Rotary plate valve systems

ABSTRACT

A rotary valve system includes a first body having a first plurality of fluid channels. The first fluid channels have a common first inlet to receive a fluid and a first outlet. The system includes a second body coupled to the first body. The second body has a second plurality of fluid channels. The second fluid channels have a second inlet and a second outlet. The system includes a plate assembly having a plate coupled between the first body and the second body. The plate is movable between at least a first, open position in which the first outlet of at least one of the first fluid channels is in fluid communication with the second inlet of at least one of the second fluid channels and a second, closed position in which the second inlet of each of the second fluid channels is substantially completely obstructed by the plate.

TECHNICAL FIELD

The present disclosure generally relates to gas turbine engines, andmore particularly relates to rotary plate valve systems for a gasturbine engine.

BACKGROUND

Gas turbine engines may be employed to power various devices. Forexample, a gas turbine engine may be employed to power a mobileplatform, such as an aircraft. In certain instances, an auxiliary powerunit (APU) may be employed prior to start-up of the gas turbine engineto provide power to various consumers, such as a heating and ventilationsystem onboard the aircraft, for example. As the APU is operating, bleedair may also be extracted from the APU and supplied to an air turbinestarter motor to start the gas turbine engine. In order to supply thebleed air to the APU, a butterfly valve may be employed. Often times,the butterfly valve may result in high pressure losses due to thegeometry of the butterfly valve. In addition, the geometry of thebutterfly valve may require large forces to open and close the valveunder load. The large forces require the use of larger actuators, whichin turn, increases a weight and a volume associated with the butterflyvalve.

Accordingly, it is desirable to provide a rotary plate valve system fora gas turbine engine, which reduces pressure losses through the valve.It is also desirable to provide a rotary plate valve system thatprovides lower forces for opening and closing the valve under load. Byproviding lower forces for opening and closing the valve under load, asmaller actuator may be employed, which reduces a weight and a volumeassociated with the rotary plate valve system. Furthermore, otherdesirable features and characteristics of the present invention willbecome apparent from the subsequent detailed description and theappended claims, taken in conjunction with the accompanying drawings andthe foregoing technical field and background.

SUMMARY

According to various embodiments, a rotary valve system is provided. Therotary valve system includes a first valve body having a first pluralityof fluid channels. Each one of the first plurality of fluid channels hasa common first inlet to receive a fluid and a first outlet. The rotaryvalve system includes a second valve body coupled to the first valvebody. The second valve body has a second plurality of fluid channels.Each one of the second plurality of fluid channels has a second inletand a second outlet. The rotary valve system includes a plate assembly.The plate assembly includes a plate coupled between the first valve bodyand the second valve body. The plate defines a plurality of openings.The plate is movable between at least a first, open position in whichthe first outlet of at least one of the first plurality of fluidchannels is in fluid communication with the second inlet of at least oneof the second plurality of fluid channels and a second, closed positionin which the second inlet of each of the second plurality of fluidchannels is substantially completely obstructed by the plate.

Further, a rotary valve system is provided according to variousembodiments. The rotary valve system includes a first valve body havinga first plurality of fluid channels. Each one of the first plurality offluid channels has a common first inlet to receive a fluid and a firstoutlet. The first plurality of fluid channels diverges downstream of thecommon first inlet. The rotary valve system includes a second valve bodycoupled to the first valve body. The second valve body has a secondplurality of fluid channels. Each one of the second plurality of fluidchannels has a second inlet and a common second outlet. The rotary valvesystem includes a plate assembly. The plate assembly has a plate coupledbetween the first valve body and the second valve body. The platedefines a plurality of openings. The plate is movable between at least afirst, open position in which each first outlet of the first pluralityof fluid channels is in fluid communication with a respective secondinlet of the second plurality of fluid channels and a second, closedposition in which the second inlet of each of the second plurality offluid channels is substantially completely obstructed by the plate.

In addition, in accordance with various embodiments, a rotary valvesystem is provided. The rotary valve system includes a first valve bodyhaving a first plurality of fluid channels. Each one of the firstplurality of fluid channels has a common first inlet to receive a fluidand a first outlet. The rotary valve system includes a second valve bodycoupled to the first valve body. The second valve body has a secondplurality of fluid channels. Each one of the second plurality of fluidchannels has a second inlet and a second outlet. The second plurality offluid channels converge within the second valve body downstream from thesecond inlet. The rotary valve system includes a plate assembly. Theplate assembly has a plate coupled between the first valve body and thesecond valve body. The plate defines a plurality of openings. The plateis movable between at least a first, open surge position in which thefirst outlet of a first sub-plurality of the first plurality of fluidchannels is in fluid communication with the second inlet of a firstsub-plurality of the second plurality of fluid channels, a second,closed position in which the second inlet of each of the secondplurality of fluid channels is substantially completely obstructed bythe plate, and a third, open load position in which the first outlet ofa second sub-plurality of the first plurality of fluid channels is influid communication with the second inlet of a second sub-plurality ofthe second plurality of fluid channels.

DESCRIPTION OF THE DRAWINGS

The exemplary embodiments will hereinafter be described in conjunctionwith the following drawing figures, wherein like numerals denote likeelements, and wherein:

FIG. 1 is a functional block diagram illustrating a mobile platform,such as an aircraft, that includes an exemplary rotary plate valvesystem having a rotary plate valve and an actuator in accordance withthe various teachings of the present disclosure;

FIG. 2 is a perspective view of the rotary plate valve system of FIG. 1;

FIG. 3 is a cross-sectional view of the rotary plate valve system ofFIG. 2, taken along line 3-3 of FIG. 2;

FIG. 4 is an end view of a first valve body of the rotary plate valve ofthe rotary plate valve system of FIG. 2;

FIG. 5 is an end view of a second valve body of the rotary plate valveof the rotary plate valve system of FIG. 2;

FIG. 6 is an expanded view of the rotary plate valve system of FIG. 2;

FIG. 7 is a perspective view of a portion of a plate assembly of therotary plate valve of the rotary plate valve system of FIG. 2;

FIG. 8 is an end view of the second valve body of the rotary plate valveof FIG. 2, in which the rotary plate valve is in a second, closedposition (0% open position);

FIG. 8A is an end view of the second valve body of the rotary platevalve of FIG. 2, in which the rotary plate valve is in about a 25% openposition;

FIG. 8B is an end view of the second valve body of the rotary platevalve of FIG. 2, in which the rotary plate valve is in about a 50% openposition;

FIG. 8C is an end view of the second valve body of the rotary platevalve of FIG. 2, in which the rotary plate valve is in about a 75% openposition;

FIG. 8D is an end view of the second valve body of the rotary platevalve of FIG. 2, in which the rotary plate valve is in a first, openposition (100% open position);

FIG. 9 is a perspective view of another exemplary rotary plate valvesystem having a rotary plate valve for use with the aircraft of FIG. 1;

FIG. 10 is a cross-sectional view of the rotary plate valve system ofFIG. 9, taken along line 10-10 of FIG. 9;

FIG. 11 is a perspective view of a portion of a plate assembly of therotary plate valve of the rotary plate valve system of FIG. 9;

FIG. 12 is a perspective view of another exemplary rotary plate valvesystem having a rotary plate valve and the actuator for use with theaircraft of FIG. 1;

FIG. 13 is an expanded view of the rotary plate valve system of FIG. 12;

FIG. 13A is an end view of a first valve body of the rotary plate valveof the rotary plate valve system of FIG. 12;

FIG. 14 is a cross-sectional view of the rotary plate valve system ofFIG. 12, taken along line 14-14 of FIG. 12;

FIG. 15 is an end view of the rotary plate valve system of FIG. 12;

FIG. 16 is a perspective view of a plate for use with the rotary valvesystem of FIG. 12;

FIG. 17 is an end view of the second valve body of the rotary platevalve of FIG. 12, in which the rotary plate valve is in a second, closedposition (0% open position);

FIG. 17A is an end view of the second valve body of the rotary platevalve of FIG. 12, in which the rotary plate valve is a surge valve andis in a first, full surge open position (100% open for surge fluidflow);

FIG. 17B is an end view of the second valve body of the rotary platevalve of FIG. 12, in which the rotary plate valve is a load valve and isin about a 25% open position (25% open for load fluid flow);

FIG. 17C is an end view of the second valve body of the rotary platevalve of FIG. 12, in which the rotary plate valve is a load valve and isin about a 50% open position (50% open for load fluid flow);

FIG. 17D is an end view of the second valve body of the rotary platevalve of FIG. 12, in which the rotary plate valve is a load valve and isin about a 75% open position (75% open for load fluid flow); and

FIG. 17E is an end view of the second valve body of the rotary platevalve of FIG. 12, in which the rotary plate valve is a load valve and isin about a 100% open position (100% open for load fluid flow).

DETAILED DESCRIPTION

The following detailed description is merely exemplary in nature and isnot intended to limit the application and uses. Furthermore, there is nointention to be bound by any expressed or implied theory presented inthe preceding technical field, background, brief summary or thefollowing detailed description. In addition, those skilled in the artwill appreciate that embodiments of the present disclosure may bepracticed in conjunction with any type of system that would benefit fromcontrolling fluid flow through a duct, and that the rotating plate valvedescribed herein for use with a gas turbine engine and an auxiliarypower unit (APU) is merely one exemplary embodiment according to thepresent disclosure. Moreover, while the rotating plate valve isdescribed herein as being used with a gas turbine engine onboard amobile platform, such as a bus, motorcycle, train, motor vehicle, marinevessel, aircraft, rotorcraft and the like, the various teachings of thepresent disclosure can be used with a gas turbine engine on a stationaryplatform. Further, it should be noted that many alternative oradditional functional relationships or physical connections may bepresent in an embodiment of the present disclosure. In addition, whilethe figures shown herein depict an example with certain arrangements ofelements, additional intervening elements, devices, features, orcomponents may be present in an actual embodiment. It should also beunderstood that the drawings are merely illustrative and may not bedrawn to scale.

As used herein, the term module refers to any hardware, software,firmware, electronic control component, processing logic, and/orprocessor device, individually or in any combination, including withoutlimitation: application specific integrated circuit (ASIC), anelectronic circuit, a processor (shared, dedicated, or group) and memorythat executes one or more software or firmware programs, a combinationallogic circuit, and/or other suitable components that provide thedescribed functionality.

Embodiments of the present disclosure may be described herein in termsof schematic, functional and/or logical block components and variousprocessing steps. It should be appreciated that such block componentsmay be realized by any number of hardware, software, and/or firmwarecomponents configured to perform the specified functions. For example,an embodiment of the present disclosure may employ various integratedcircuit components, e.g., memory elements, digital signal processingelements, logic elements, look-up tables, or the like, which may carryout a variety of functions under the control of one or moremicroprocessors or other control devices. In addition, those skilled inthe art will appreciate that embodiments of the present disclosure maybe practiced in conjunction with any number of systems, and that themobile platform or aircraft systems described herein is merely anexemplary embodiment of the present disclosure.

For the sake of brevity, conventional techniques related to signalprocessing, data transmission, signaling, control, and other functionalaspects of the systems (and the individual operating components of thesystems) may not be described in detail herein. Furthermore, theconnecting lines shown in the various figures contained herein areintended to represent example functional relationships and/or physicalcouplings between the various elements. It should be noted that manyalternative or additional functional relationships or physicalconnections may be present in an embodiment of the present disclosure.

As used herein, the term “axial” refers to a direction that is generallyparallel to or coincident with an axis of rotation, axis of symmetry, orcenterline of a component or components. For example, in a cylinder ordisc with a centerline and generally circular ends or opposing faces,the “axial” direction may refer to the direction that generally extendsin parallel to the centerline between the opposite ends or faces. Incertain instances, the term “axial” may be utilized with respect tocomponents that are not cylindrical (or otherwise radially symmetric).For example, the “axial” direction for a rectangular housing containinga rotating shaft may be viewed as a direction that is generally parallelto or coincident with the rotational axis of the shaft. Furthermore, theterm “radially” as used herein may refer to a direction or arelationship of components with respect to a line extending outward froma shared centerline, axis, or similar reference, for example in a planeof a cylinder or disc that is perpendicular to the centerline or axis.In certain instances, components may be viewed as “radially” alignedeven though one or both of the components may not be cylindrical (orotherwise radially symmetric). Furthermore, the terms “axial” and“radial” (and any derivatives) may encompass directional relationshipsthat are other than precisely aligned with (e.g., oblique to) the trueaxial and radial dimensions, provided the relationship is predominatelyin the respective nominal axial or radial direction. As used herein, theterm “transverse” denotes an axis that crosses another axis at an anglesuch that the axis and the other axis are neither substantiallyperpendicular nor substantially parallel.

With reference to FIG. 1, a rotary plate valve system 10 is shown. Inone example, the rotary plate valve system 10 is shown coupled to and influid communication with a bleed supply inlet duct 14 to receive bleedfluid, such as bleed air. The bleed supply inlet duct 14 is coupled toand in fluid communication with a base collector 16 of an APU 18 toreceive the bleed air. In this example, the APU 18 is onboard anaircraft 20, and the bleed air is selectively provided by the rotaryplate valve system 10 to other components or systems associated with theaircraft 20, such as a gas turbine engine 8, via at least one outletduct 22. The rotary plate valve system 10 includes a rotary plate valve24 and an actuator 26. As will be discussed, the actuator 26 isresponsive to one or more control signals from a controller 28associated with the APU 18 or the aircraft 20 to move the rotary platevalve 24 to a first, open position (in which bleed air flows through theoutlet duct 22), a second, closed position (in which bleed air does notflow through the outlet duct 22) and various positions in between thefirst, open position and the second closed position to provide modulatedflow.

With reference to FIGS. 2 and 3, the rotary plate valve system 10 isshown in greater detail. The rotary plate valve 24 includes a firstvalve body 30, a second valve body 32 and a plate assembly 34. The firstvalve body 30 includes a first end 36 and an opposite second end 38. Thefirst end 36 is coupled to the bleed supply inlet duct 14 (FIG. 1) andthe second end 38 is coupled to the second valve body 32. With referenceto FIG. 3, the first end 36 includes a first flange 36.1 that is annularand surrounds the first end 36 of the first valve body 30. The firstflange 36.1 defines a first counterbore 40 and second counterbore 42that each extend about a perimeter or circumference of the first flange36.1. The first counterbore 40 and the second counterbore 42 are definedthrough the first flange 36.1 and cooperate to enable a portion of thebleed supply inlet duct 14 (FIG. 1) to be received within and fluidlycoupled to the first valve body 30. In one example, the firstcounterbore 40 defines a plurality of threads 40.1. The plurality ofthreads 40.1 threadably engage with a plurality of threads of the bleedsupply inlet duct 14 (FIG. 1) to couple the bleed supply inlet duct 14to the first valve body 30. It should be noted that the use of the firstcounterbore 40 and the second counterbore 42 for coupling the bleedsupply inlet duct 14 (FIG. 1) to the rotary plate valve 24 is merelyexemplary, any suitable technique may be employed to couple the bleedsupply inlet duct 14 to the first valve body 30, including, but notlimited to, one or more flanges, welding, mechanical fasteners, etc. Thesecond counterbore 42 defines a common first inlet 42.1 for each of afirst plurality of fluid channels 44 defined in the first valve body 30from the first end 36 to the second end 38. An exterior surface 30.1 ofthe first valve body 30 is substantially smooth, and is shaped tocorrespond with the shape of the first plurality of fluid channels 44.In one example, the exterior surface 30.1 tapers from the second end 38toward the first end 36. The first valve body 30 has an interior surface30.2 that is opposite the exterior surface 30.1.

The second end 38 defines a second annular flange 38.1 (FIG. 4). Thesecond annular flange 38.1 defines a third counterbore 46 and a firstbearing groove 48 that each extend about a perimeter or circumference ofthe second annular flange 38.1. The third counterbore 46 defines arecess within the second end 38 for receiving a portion of the plateassembly 34. The first bearing groove 48 is defined within a surface46.1 of the third counterbore 46, and receives a portion of the plateassembly 34. The second end 38 may also define a gear housing portion49. The gear housing portion 49 is substantially cylindrical, andextends outwardly from the exterior surface 30.1 of the first valve body30. The gear housing portion 49 receives a portion of the plate assembly34 to couple the plate assembly 34 to the actuator 26.

The first plurality of fluid channels 44 is defined within the firstvalve body 30 from the first end 36 to the second end 38. In thisexample, with reference to FIG. 4, the first valve body 30 includes fourfirst fluid channels 44.1-44.4. Each of the first fluid channels44.1-44.4 are spaced apart about a perimeter or circumference of thefirst valve body 30. Each of the first fluid channels 44.1-44.4 includesthe common first inlet 42.1 and a respective first outlet 50.1-50.4. Aswill be discussed, each of the first outlets 50.1-50.4 are selectivelyin fluid communication with the second valve body 32 based on a positionof the plate assembly 34.

With reference to FIG. 4, each of the first fluid channels 44.1-44.4 isdefined by a pair of sidewalls 52.1, 52.2, a conical flange 52.3 and theinterior surface 30.2. The sidewalls 52.1, 52.2 of adjacent ones of thefirst fluid channels 44.1-44.4 are interconnected via a rib 52.4.Generally, the sidewalls 52.1, 52.2 cooperate to form a substantiallytriangular shape that extends from the first end 36 to the conicalflange 52.3. In one example, the sidewalls 52.1, 52.2 are coupled to theconical flange 52.3 downstream from the common first inlet 42.1. In thisexample, with reference to FIG. 3, the sidewalls 52.1, 52.2 form acommon wall 53 that extends along a length L2 from the common firstinlet 42.1 to a divergence point 54 defined at the conical flange 52.3.The divergence point 54 is selected to provide reduced fluid andpressure losses as the fluid flows through the first valve body 30 intothe second valve body 32. In one example, the divergence point 54 isabout 0.5 inches (in.) (25.4 millimeters (mm.)) downstream from thecommon first inlet 42.1 at the first end 36. Generally, the divergencepoint 54 may be located between the common first inlet 42.1 and anylocation downstream of common first inlet 42.1 within the first valvebody 30 based on the specific installation environment of the rotaryplate valve 24. By diverging at the divergence point 54 defined by theconical flange 52.3, the first fluid channels 44.1-44.4 also enable aportion of the plate assembly 34 to be received within the second end 38of the first valve body 30. In this regard, the conical flange 52.3defines a first cavity 56 within the second end 38 of the first valvebody 30. The first cavity 56 is surrounded by the first fluid channels44.1-44.4 and enables the receipt of a portion of the plate assembly 34.

The first fluid channels 44.1-44.4 diverge outwardly or away from alongitudinal axis L defined through the rotary plate valve 24. Each ofthe first fluid channels 44.1-44.4 are bounded by the sidewalls 52.1,52.2 and the interior surface 30.2 such that downstream from the commoninlet 42.1, each of the first fluid channels 44.1-44.4 is fluidlyisolated from or separate from a remainder of the first fluid channels44.1-44.4. Stated another way, the first fluid channels 44.1-44.4 definediscrete fluid channels downstream from the common inlet 42.1 such thatfluid downstream from the common inlet 42.1 does not mix between thefirst fluid flow channels 44.1-44.4. In this example, the first outlets50.1-50.4 are defined at the second end 38 of the first valve body 30.Generally, each of the first outlets 50.1-50.4 is discrete, such thatfluid flowing through the respective first fluid channels 44.1-44.4exits the respective first fluid channel 44.1-44.4 at the respectivefirst outlet 50.1-50.4. Each of the first outlets 50.1-50.4 isselectively in fluid communication with respective ones of a secondplurality of fluid channels 74 defined in the second valve body 32.

The second valve body 32 includes a third end 60 and an opposite fourthend 62. The third end 60 is coupled to the first valve body 30 and thefourth end 62 is coupled to the outlet duct 22 (FIG. 1). With referenceto FIG. 3, the third end 60 defines a third annular flange 60.1. Thethird annular flange 60.1 defines a second bearing groove 66 thatextends about a perimeter or circumference of the third annular flange60.1. The second bearing groove 66 is defined within a surface 60.2 ofthe third annular flange 60.1, and receives a portion of the plateassembly 34. The third end 60 may also define a second actuator housingportion 68. The second actuator housing portion 68 is substantiallycylindrical, and extends outwardly from an exterior surface 32.1 of thesecond valve body 32. The second actuator housing portion 68 is hollowfor receiving a portion of the actuator 26 to couple the actuator 26 tothe rotary plate valve 24. In one example, the second actuator housingportion 68 includes a pair of flanges 69, which each define athroughbore 69.1. The flanges 69 receive a mechanical fastenertherethrough, such as a bolt, screw, etc. to couple the actuator 26 tothe rotary plate valve 24.

The fourth end 62 includes a fourth flange 62.1 that is annular andsurrounds the fourth end 62 of the second valve body 32. The fourthflange 62.1 defines a fourth counterbore 70 and a fifth counterbore 72that each extend about a perimeter or circumference of the fourth flange62.1. The fourth counterbore 70 and the fifth counterbore 72 are definedthrough the fourth flange 62.1 and cooperate to enable a portion of theoutlet duct 22 (FIG. 1) to be received within and fluidly coupled to thefourth flange 62.1. In one example, the fourth counterbore 70 defines aplurality of threads 70.1. The plurality of threads 70.1 threadablyengage with a plurality of threads of the outlet duct 22 (FIG. 1) tocouple the outlet duct 22 to the second valve body 32. It should benoted that the use of the fourth counterbore 70 and the fifthcounterbore 72 for coupling the outlet duct 22 (FIG. 1) to the rotaryplate valve 24 is merely exemplary, as any suitable technique may beemployed to couple the second valve body 32 to the outlet duct 22,including, but not limited to, one or more flanges, welding, mechanicalfasteners, etc. In this example, the fifth counterbore 72 defines acommon second outlet 72.1 for each of a second plurality of fluidchannels 74 defined in the second valve body 32 from the third end 60 tothe fourth end 62. The exterior surface 32.1 of the second valve body 32is substantially smooth, and is shaped to correspond with the shape ofthe second plurality of fluid channels 74. In one example, the exteriorsurface 32.1 tapers from the third end 60 toward the fourth end 62. Thesecond valve body 32 has an interior surface 32.2 that is opposite theexterior surface 32.1.

The second plurality of fluid channels 74 is defined within the secondvalve body 32 from the third end 60 to the fourth end 62. In thisexample, with reference to FIG. 5, the second valve body 32 includesfour second fluid channels 74.1-74.4, which each correspond to one ofthe first fluid channels 44.1-44.4. Each of the second fluid channels74.1-74.4 are spaced apart about a perimeter or circumference of thesecond valve body 32. Each of the second fluid channels 74.1-74.4includes a respective second inlet 76.1-76.4 and the common secondoutlet 72.1. As will be discussed, each of the second inlets 76.1-76.4are selectively in fluid communication with the first valve body 30based on a position of the plate assembly 34.

With reference to FIG. 5, each of the second fluid channels 74.1-74.4 isdefined by a pair of sidewalls 78.1, 78.2, a second conical flange 78.3(FIG. 1) and the interior surface 32.2. The sidewalls 78.1, 78.2 ofadjacent ones of the second fluid channels 74.1-74.4 are interconnectedvia a rib 78.4. Generally, the sidewalls 78.1, 78.2 and the respectiverib 78.4 cooperate to form a substantially triangular shape that extendsfrom the second conical flange 78.3 to the fourth end 62. In oneexample, the sidewalls 78.1, 78.2 and the ribs 78.4 are coupled to thesecond conical flange 78.3 at the third end 60 to define the secondinlets 76.1-76.4. In this example, with reference to FIG. 3, the secondconical flange 78.3 includes a shaft 79 defined internally within thesecond valve body 32. As will be discussed, the shaft 79 receives and iscoupled to a portion of the plate assembly 34. In one example, the shaft79 defines a plurality of threads 79.1 and a groove 79.2. The pluralityof threads 79.1 matingly engages with a portion of the plate assembly 34to couple the plate assembly 34 to the second valve body 32. The groove79.2 receives a portion of the plate assembly 34 to couple the portionof the plate assembly 34 to the shaft 79.

The sidewalls 78.1, 78.2 downstream from the second conical flange 78.3form a second common wall 80 that extends along a length L3 from aconvergence point 82 defined at the second conical flange 78.3 to thecommon second outlet 72.1. The convergence point 82 is selected toprovide reduced fluid and pressure losses as the fluid flows through thesecond valve body 32. In one example, the convergence point 82 is about0.5 inches (in.) (25.4 millimeters (mm.)) upstream from the commonsecond outlet 72.1 at the fourth end 62. Generally, the convergencepoint 82 may be located between the common second outlet 72.1 and anylocation downstream of common second outlet 72.1 within the second valvebody 32 based on the specific installation environment of the rotaryplate valve 24. By diverging prior to the convergence point 82, thesecond fluid channels 74.1-74.4 also enable a portion of the plateassembly 34 to be received within the third end 60 of the second valvebody 32. In this regard, the second conical flange 78.3 defines a secondcavity 84 within the third end 60 of the second valve body 32 thatcooperates with the first cavity 56 of the first valve body 30 toreceive a portion of the plate assembly 34. The second cavity 84 issurrounded by the second fluid channels 74.1-74.4. Generally, the secondfluid channels 74.1-74.4 diverge outwardly or away from a longitudinalaxis L defined through the rotary plate valve 24 prior to converging atthe convergence point 82. Each of the second fluid channels 74.1-74.4are bounded by the sidewalls 78.1, 78.2 and the interior surface 32.2such that upstream from the common second outlet 72.1, each of thesecond fluid channels 74.1-74.4 is fluidly isolated from or separatefrom a remainder of the second fluid channels 74.1-74.4. Stated anotherway, the second fluid channels 74.1-74.4 define discrete fluid channelsupstream from the common second outlet 72.1 such that fluid upstreamfrom the common second outlet 72.1 does not mix between the second fluidchannels 74.1-74.4. In this example, the second inlet 76.1-76.4 isdefined at the third end 60 of the second valve body 32. Generally, eachof the second inlets 76.1-76.4 is discrete, such that fluid flowingthrough the respective second fluid channels 74.1-74.4 enters therespective second fluid channels 74.1-74.4 at the respective secondinlet 76.1-76.4. Each of the second inlets 76.1-76.4 is selectively influid communication with respective ones of the first outlets 50.1-50.4defined in the first valve body 30 such that fluid from a respective oneof the first fluid channels 44.1-44.4 flows into a respective one of thesecond fluid channels 74.1-74.4 based on a position of the plateassembly 34.

In one example, each of the first fluid channels 44.1-44.4 and thesecond fluid channels 74.1-74.4 have the same flowpath area. Byproviding the first fluid channels 44.1-44.4 and the second fluidchannels 74.1-74.4 with the same flowpath area, flow and pressure lossesare reduced as the fluid flows from the first fluid channels 44.1-44.4into the second fluid channels 74.1.-74.4. In addition, each of thesidewalls 52.1, 52.2; 78.1, 78.2 include fillets along theinterconnection of the respective sidewalls 52.1, 52.2; 78.1, 78.2,which reduces flow separation through each of the first fluid channels44.1-44.4 and the second fluid channels 74.1-74.4. In addition, eachleading edge of the sidewalls 52.1, 52.2 has a radius to provide for asmooth transition into the respective first fluid channel 44.1-44.4 fromthe common first inlet 42.1 to reduce flow losses. Further, each leadingedge of the sidewalls 78.1, 78.2 has a radius to provide for a smoothtransition into the respective second fluid channel 74.1-74.4 from theplate 96, thereby reducing flow losses.

In one example, each of the first fluid channels 44.1-44.4 and thesecond fluid channels 74.1-74.4 is integrally formed, monolithic orone-piece with the first valve body 30 and the second valve body 32,respectively. In this example, the first valve body 30 and the secondvalve body 32 are composed of a metal or metal alloy. Generally, thefirst valve body 30 and the second valve body 32 are composed ofaluminum alloys or steel alloys depending upon the operating environmentof the rotary plate valve 24. It should be noted that other metals ormetal alloys may be employed, based on the particular operatingenvironment for the rotary plate valve 24. In one example, in order tomanufacture the first valve body 30 and the second valve body 32including the first fluid channels 44.1-44.4 and the second fluidchannels 74.1-74.4, respectively, a core that defines the first valvebody 30 including the first fluid channels 44.1-44.4 is cast, molded orprinted from a ceramic material; and a core that defines the secondvalve body 32 including the second fluid channels 74.1-74.4 is cast,molded or printed from a ceramic material. In this example, the core ismanufactured from a ceramic using ceramic additive manufacturing orselective laser sintering. With the core formed, the core is positionedwithin a die. With the core positioned within the die, the die isinjected with liquid wax such that liquid wax surrounds the core. A waxsprue or conduit may also be coupled to the cavity within the die to aidin the formation of the first valve body 30 and the second valve body32. Once the wax has hardened to form a wax pattern, the wax pattern iscoated or dipped in ceramic to create a ceramic mold about the waxpattern. After coating the wax pattern with ceramic, the wax pattern maybe subject to stuccoing and hardening. The coating, stuccoing andhardening processes may be repeated until the ceramic mold has reachedthe desired thickness.

With the ceramic mold at the desired thickness, the wax is heated tomelt the wax out of the ceramic mold. With the wax melted out of theceramic mold, voids remain surrounding the core, and the ceramic mold isfilled with molten metal or metal alloy. In one example, the moltenmetal is poured down an opening created by the wax sprue. It should benoted, however, that vacuum drawing may be used to fill the ceramic moldwith the molten metal. Once the metal or metal alloy has solidified, theceramic is removed from the metal or metal alloy, through chemicalleaching, for example, leaving the first fluid channels 44.1-44.4 formedin the first valve body 30 and the second fluid channels 74.1-74.4formed in the second valve body 32. It should be noted thatalternatively, the first fluid channels 44.1-44.4 and the second fluidchannels 74.1-74.4 may be formed in the first valve body 30 and thesecond valve body 32, respectively, using conventional dies with one ormore portions of the core (or portions adjacent to the core) comprisinga fugitive core insert. As a further alternative, the first valve body30 and the second valve body 32 including the first fluid channels44.1-44.4 and the second fluid channels 74.1-74.4, respectively, may beformed using other additive manufacturing processes, including, but notlimited to, direct metal laser sintering. It should be noted that theuse of four of the first fluid channels 44.1-44.4 and the second fluidchannels 74.1-74.4 is merely exemplary, as the first valve body 30 andthe second valve body 32 may define any number of corresponding fluidchannels.

With reference to FIG. 6, the plate assembly 34 is shown expanded fromthe first valve body 30 and the second valve body 32. In one example,the plate assembly 34 includes a coupling member 90, a first bearingring 92, a bearing 94, a plate 96, a gear 98 and a second bearing ring100. It should be noted that while plate assembly 34 is described andillustrated herein as including the first bearing ring 92, the bearing94 and the second bearing ring 100, the plate assembly 34 may includeone or more bushing rings, bushings, or other devices that enablerotation of the plate 96 relative to the first valve body 30 and thesecond valve body 32.

The coupling member 90 couples and retains the plate assembly 34 on thesecond valve body 32. In one example, the coupling member 90 is a flangenut having a plurality of threads 90.1 that matingly engage with theplurality of threads 79.1 of the shaft 79 (FIG. 3). The coupling member90 retains the bearing 94, and thus, the plate 96, the first bearingring 92 and the second bearing ring 100 on the shaft 79 of the secondvalve body 32. The coupling member 90 may be composed of a metal, metalalloy or polymer, and may be cast, forged, stamped or formed withadditive manufacturing, including, but not limited to, direct metallaser sintering.

The first bearing ring 92 facilitates the rotation of the plate 96relative to the first valve body 30. The first bearing ring 92 includesa plurality of ball bearings 92.1, which are coupled to a ring body92.2. Generally, the plurality of ball bearings 92.1 are coupled to thering body 92.2 so as to spaced apart about a perimeter or circumferenceof the ring body 92.2. The plurality of ball bearings 92.1 arepositioned within the first bearing groove 48 defined in the second end38 of the first valve body 30, and roll within a first plate bearinggroove 102 (FIG. 3) defined in a first side 96.1 of the plate 96. Theplurality of ball bearings 92.1 and the ring body 92.2 may be composedof a metal, metal alloy or polymer, and may be stamped, forged, cast,etc. Once the ring body 92.2 is formed, each of the ball bearings 92.1may be coupled to the ring body 92.2. The ring body 92.2 may alsoinclude an arcuate relief 92.3 about a portion of the perimeter of thering body 92.2 to provide clearance for the engagement between the plate96 and the gear 98. The ring body 92.2 may also include a seal 93 on theside of the ring body 92.2 that faces the first valve body 30 (FIG. 3).Generally, the seal 93 extends axially outward from the ring body 92.2between adjacent ones of the plurality of ball bearings 92.1 to inhibitfluid flow through the first bearing ring 92.

The bearing 94 is received within the groove 79.2 of the shaft 79 and iscoupled to the plate 96. In one example, the bearing 94 is a ballbearing, with an inner race 94.1 coupled to the groove 79.2 on the shaft79 (FIG. 3) and an outer race 94.2 coupled to the plate 96 (FIG. 3). Itshould be noted that the bearing 94 may also comprise a roller bearing,if desired.

The plate 96 is circular, and includes the first side 96.1 and anopposite second side 96.2. The plate 96 is coupled between the firstvalve body 30 and the second valve body 32. The first side 96.1 includesthe first plate bearing groove 102 defined about a majority of aperimeter or circumference of the first side 96.1, and faces the secondend 38 of the first valve body 30. The second side 96.2 includes asecond plate bearing groove 104 defined about a majority of a perimeteror circumference of the second side 96.2, and faces the third end 60 ofthe second valve body 32. In this regard, the plate 96 also defines aplurality of plate gear teeth 106, a plurality of openings 108 and acentral opening 110. The plurality of plate gear teeth 106 are definedalong the perimeter or circumference of the plate 96 and interrupt thefirst plate bearing groove 102 and the second plate bearing groove 104.The plurality of plate gear teeth 106 meshingly engage with the gear 98to enable the plate 96 to be driven or rotated by the actuator 26.Generally, the plurality of plate gear teeth 106 extend along theperimeter of the plate 96 for a predetermined arc length that allows forthe correct timing of the rotation of the plate 96 and allows for thepredetermined rotational angle needed to open each of the second fluidchannels 74.1-74.4. Generally, the arc length is predetermined based onthe number of flow paths incorporated into the rotary plate valve 24.

The plurality of openings 108 are defined through the plate 96 from thefirst side 96.1 to the second side 96.2. The plurality of openings 108are spaced apart about the perimeter or circumference of the plate 96.Generally, each of the plurality of openings 108 corresponds to one ofthe first fluid channels 44.1-44.4 and one of the second fluid channels74.1-74.4. Thus, in this example, with reference to FIG. 7, the plate 96includes four openings 108.1-108.4, which each have the same flowpatharea as the first fluid channels 44.1-44.4 and the second fluid channels74.1-74.4. The openings 108.1-108.4 are sized such that a section109.1-109.4 of the plate 96 between adjacent ones of the openings108.1-108.4 is the same size as the adjacent opening 108.1-108.4. Thisprovides for the second, closed position of the rotary plate valve 24.Stated another way, the sections 109.1-109.4 are sized to completelyobstruct the flow of fluid between the first fluid channels 44.1-44.4and the second fluid channels 74.1-74.4, thereby providing the second,closed position of the rotary plate valve 24. When the openings108.1-108.4 are fully or completely aligned with the first fluidchannels 44.1-44.4 and the second fluid channels 74.1-74.4, the rotaryplate valve 24 is in the first, open position such that fluid flows fromthe first fluid channels 44.1-44.4 into and through the second fluidchannels 74.1-74.4.

The openings 108.1-108.4 are shaped to correspond with the shape of thefirst outlets 50.1-50.4 and the second inlets 76.1-76.4. In one example,each of the openings 108.1-108.4 is defined by a first arc segment 112,an opposite second arc segment 114 and a pair of radial segments 116.1,116.2. The first arc segment 112 is radially inward from the second arcsegment 114. The second arc segment 114 extends along an arc that isgreater than an arc of the first arc segment 112. The pair of radialsegments 116.1, 116.2 interconnect the first arc segment 112 and thesecond arc segment 114.

With reference to FIG. 3, the central opening 110 includes a flange110.1 that couples the plate 96 to the bearing 94. The flange 110.1extends axially from the second side 96.2 about the circumference of thecentral opening 110. The flange 110.1 includes a lip 110.2, whichretains the plate 96 on the bearing 94. The plate 96 is composed of ametal or metal alloy, and may be cast, forged, stamped or formed withadditive manufacturing, including, but not limited to, direct metallaser sintering.

With reference to FIG. 6, the gear 98 is coupled to the actuator 26 andis driven by the actuator 26 to move or drive the plate 96. The gear 98is retained within the gear housing portion 49. The gear 98 includes aplurality of gear teeth 98.1 defined about a perimeter or circumferenceof the gear 98. The plurality of gear teeth 98.1 meshingly engage withthe plurality of plate gear teeth 106 of the plate 96 to move or drivethe plate 96. In one example, the gear 98 is a spur gear; however, thegear 98 may have different configurations based on the orientation ofthe gear 98 relative to the plate 96. The gear 98 is composed of a metalor metal alloy, and may be cast, forged, stamped, etc.

The second bearing ring 100 facilitates the rotation of the plate 96relative to the second valve body 32. As the second bearing ring 100 issubstantially the same as the first bearing ring 92, the second bearingring 100 will not be discussed in detail herein. The second bearing ring100 includes the plurality of ball bearings 92.1, which are coupled tothe ring body 92.2. The ring body 92.2 may also include the arcuaterelief 92.3 about a portion of the perimeter of the ring body 92.2 toprovide clearance for the engagement between the plate 96 and the gear98 (FIG. 7). The ring body 92.2 may also include the seal 93 on the sideof the ring body 92.2 that faces the second valve body 32 (FIG. 3). Theplurality of ball bearings 92.1 of the second bearing ring 100 arepositioned within the second bearing groove 66 defined in the third end60 of the second valve body 32, and roll within the second plate bearinggroove 104 defined in the second side 96.2 of the plate 96.

The actuator 26 is in communication with the controller 28 (FIG. 1) toreceive one or more control signals to drive the gear 98, and thus, theplate 96 between the first, open position, the second, closed positionand positions in-between. The actuator 26 includes a motor 120 and anoutput shaft 122. The motor 120 may comprise a suitable electric motorthat is responsive to the controller 28 (FIG. 1). Generally, the motor120 is in communication with the controller 28 (FIG. 1) and isresponsive to the one or more control signals to rotate the output shaft122 in a clockwise or counterclockwise direction for a predefinedperiod. In one example, the one or more control signals command therotation of the output shaft 122 for a predefined period of time, whichcorresponds to a desired angular movement of the plate 96. It should benoted that other techniques may be employed to rotate the plate 96 withthe actuator 26. The output shaft 122 is fixedly coupled to the gear 98such that the gear 98 rotates with the output shaft 122. The rotation ofthe gear 98 clockwise or counterclockwise by the output shaft 122rotates the plate 96 relative to the first valve body 30 and the secondvalve body 32. The actuator 26 may also include a pair of mating flanges124. The mating flanges 124 each include a throughbore 126, whichreceives mechanical fasteners for coupling the actuator 26 to the rotaryplate valve 24. It should be noted that the use of the pair of matingflanges 124 is merely exemplary, as any suitable technique may be usedto couple the actuator 26 to the rotary plate valve 24.

With reference to FIG. 1, the controller 28 includes at least oneprocessor 130 and a computer readable storage device or media 132. Theprocessor 130 can be any custom made or commercially availableprocessor, a central processing unit (CPU), a graphics processing unit(GPU), an auxiliary processor among several processors associated withthe controller 28, a semiconductor based microprocessor (in the form ofa microchip or chip set), a macroprocessor, any combination thereof, orgenerally any device for executing instructions. The computer readablestorage device or media 132 may include volatile and nonvolatile storagein read-only memory (ROM), random-access memory (RAM), and keep-alivememory (KAM), for example. KAM is a persistent or non-volatile memorythat may be used to store various operating variables while theprocessor 130 is powered down. The computer-readable storage device ormedia 132 may be implemented using any of a number of known memorydevices such as PROMs (programmable read-only memory), EPROMs(electrically PROM), EEPROMs (electrically erasable PROM), flash memory,or any other electric, magnetic, optical, or combination memory devicescapable of storing data, some of which represent executableinstructions, used by the controller 28 in controlling componentsassociated with the rotary plate valve system 10.

The instructions may include one or more separate programs, each ofwhich comprises an ordered listing of executable instructions forimplementing logical functions. The instructions, when executed by theprocessor 130, receive and process input signals, perform logic,calculations, methods and/or algorithms for controlling the componentsof the rotary plate valve system 10 of the aircraft 12, and generatecontrol signals to the actuator 26 of the rotary plate valve system 10to control a position of the plate 96 based on the logic, calculations,methods, and/or algorithms. Although only one controller 28 is shown inFIG. 1, embodiments of the aircraft 12 may include any number ofcontrollers 28 that communicate over any suitable communication mediumor a combination of communication mediums and that cooperate to processthe sensor signals, perform logic, calculations, methods, and/oralgorithms, and generate control signals to control features of therotary plate valve system 10.

In various embodiments, one or more instructions of the controller 28are associated with the rotary plate valve system 10 and, when executedby the processor 130, the instructions output one or more controlsignals to the actuator 26 to move the plate 96, and thus, the rotaryplate valve 24 between the first, open position, the second, closedposition and positions in-between. In various embodiments, a rotaryvalve control system may include one or more control modules embeddedwithin the controller 28 for controlling the actuator 26. The rotaryvalve control system may include a closed or an open loop controlmethodology that controls the actuator 26 to move the plate 96 to apredetermined position based on input signals received from varioussensors or systems associated with the aircraft 12, or in otherembodiments, the rotary valve control system may be an internal openloop control system that controls the actuator 26 based on inputreceived to the rotary valve control system. In certain embodiments, therotary valve control system may comprise a combination of the two. Dueto the nature and capability of the rotating plate 96, the actuator 26can be used to modulate the position of the plate 96 such that amodulated fluid flow results from the exit of the rotary plate valve 24.

In one example, in order to assemble the rotary plate valve system 10,with the second valve body 32 formed and the second bearing ring 100formed and assembled, the second bearing ring 100 is positioned withinthe second bearing groove 66 of the second valve body 32 such that theseal 93 is against the second valve body 32. With the plate 96 formed,the bearing 94 is positioned within the plate 96 so that it abuts thelip 110.2 of the flange 110.1. The plate 96 with the bearing 94 ispositioned about the shaft 79, and the coupling member 90 is coupled tothe shaft 79 such that the plurality of threads 90.1 threadably engagewith the plurality of threads 79.1 of the shaft 79 to retain the plate96 on the shaft 79. With the first bearing ring 92 formed and assembled,the first bearing ring 92 is coupled to the first valve body 30 so thatthe seal 93 is positioned against the first bearing groove 48 of thefirst valve body 30. The first valve body 30 is coupled to the secondvalve body 32. With the gear 98 formed, the gear 98 is positioned withinthe gear housing portion 49 of the first valve body 30 such that theplurality of gear teeth 98.1 mesh with the plurality of plate gear teeth106 of the plate 96. The output shaft 122 is inserted through the secondactuator housing portion 68 of the second valve body 32 and is fixedlycoupled to the gear 98, via a press-fit, for example. With thethroughbores 126 of the mating flanges 124 coaxially aligned with thethroughbores 69.1 of the flanges 69 of the second actuator housingportion 68 of the second valve body 32, the mechanical fasteners areinserted to couple the actuator 26 to the rotary plate valve 24.

With the rotary plate valve system 10 assembled, in the example of FIG.1, the bleed supply inlet duct 14 is coupled to the first end 36 of thefirst valve body 30, and the outlet duct 22 is coupled to the fourth end62 of the second valve body 32. The actuator 26 is placed incommunication with the controller 28 via a communication architecturethat enables the transfer of commands, power, data, etc., such as a bus.Initially, the rotary plate valve system 10 is in the second, closedposition, as shown in FIG. 8. Based on the receipt of one or morecontrol signals from the controller 28, the motor 120 drives the outputshaft 122 to rotate the gear 98 (FIG. 6) in a clockwise direction tomove the plate 96 and thus, the rotary plate valve 24 toward the first,open position. In one example, upon receipt of one or more controlsignals to move the rotary plate valve 24 to about a 25% open position,with reference to FIG. 8A, the actuator 26 rotates the gear 98 (FIG. 7)clockwise for a predetermined rotational angle that corresponds to amovement of the plate 96 that results in about a 75% blockage orobstruction of flow through the respective second inlets 76.1-76.4.Stated another way, the actuator 26 rotates the gear 98 clockwise tomove the plate 96 such that the sections 109.1-109.4 obscure or coverabout 75% of each of the respective second inlets 76.1-76.4, as shown inFIG. 8A. In the 25% open position, the rotary plate valve 24 providesmodulated fluid flow from the bleed supply inlet duct 14 to the outletduct 22.

In another example, with reference to FIG. 8B, based on the receipt ofone or more control signals from the controller 28, the motor 120 drivesthe output shaft 122 to rotate the gear 98 in a clockwise direction tomove the plate 96 and thus, the rotary plate valve 24 to about a 50%open position. In this example, the actuator 26 rotates the gear 98(FIG. 7) clockwise for a predetermined rotational angle that correspondsto a movement of the plate 96 that results in about a 50% blockage orobstruction of flow through the respective second inlets 76.1-76.4.Stated another way, the actuator 26 rotates the gear 98 clockwise tomove the plate 96 such that the sections 109.1-109.4 obscure or coverabout 50% of each of the respective second inlets 76.1-76.4, as shown inFIG. 8B. In the 50% open position, the rotary plate valve 24 providesmodulated fluid flow from the bleed supply inlet duct 14 to the outletduct 22.

In another example, with reference to FIG. 8C, based on the receipt ofone or more control signals from the controller 28, the motor 120 drivesthe output shaft 122 to rotate the gear 98 in a clockwise direction tomove the plate 96 and thus, the rotary plate valve 24 to about a 75%open position. In this example, the actuator 26 rotates the gear 98(FIG. 7) clockwise for a predetermined rotational angle that correspondsto a movement of the plate 96 that results in about a 25% blockage orobstruction of flow through the respective second inlets 76.1-76.4.Stated another way, the actuator 26 rotates the gear 98 clockwise tomove the plate 96 such that the sections 109.1-109.4 obscure or coverabout 25% of each of the respective second inlets 76.1-76.4, as shown inFIG. 8C. In the 75% open position, the rotary plate valve 24 providesmodulated fluid flow from the bleed supply inlet duct 14 to the outletduct 22.

As a further example, with reference to FIG. 8D, based on the receipt ofone or more control signals from the controller 28, the motor 120 drivesthe output shaft 122 to rotate the gear 98 in a clockwise direction tomove the plate 96 and thus, the rotary plate valve 24 to the first, openposition. In this example, the actuator 26 rotates the gear 98 (FIG. 7)clockwise for a predetermined rotational angle that corresponds to amovement of the plate 96 that results in about a 0% blockage orobstruction of flow through the respective second inlets 76.1-76.4.Stated another way, the actuator 26 rotates the gear 98 clockwise tomove the plate 96 such that the sections 109.1-109.4 are hidden and donot cover the respective second inlets 76.1-76.4. Thus, in the first,open position, each of the second inlets 76.1-76.4 are unobstructed bythe sections 109.1-109.4 and the rotary plate valve 24 is 100% open suchthat the first outlets 50.1-50.4 are in complete fluid communicationwith the second inlets 76.1-76.4. In the first, open position, therotary plate valve 24 provides full fluid flow from the bleed supplyinlet duct 14 to the outlet duct 22.

In addition, based on the receipt of one or more control signals fromthe controller 28, the motor 120 drives the output shaft 122 to rotatethe gear 98 in a counterclockwise direction to move the plate 96 andthus, the rotary plate valve 24 toward the second, closed position. Inthe second, closed position, each of the second inlets 76.1-76.4 iscompletely obstructed by the sections 109.1-109.4 such that no fluidflows from the first outlets 50.1-50.4 to the second inlets 76.1-76.4,and the rotary plate valve 24 is 0% open (FIG. 8). In the second, closedposition, the rotary plate valve 24 provides substantially zero fluidflow from the bleed supply inlet duct 14 to the outlet duct 22. Itshould be noted that the clockwise movement of the gear 98 describedherein is merely exemplary, as the gear 98 may also be configured tomove in a counterclockwise direction to move the plate 96 to theselected position. Moreover, it should be understood that the plate 96is actively movable by the actuator 26 via the controller 28 to anyposition between the second, closed position (FIG. 8) and the first,open position (FIG. 8D) based on a downstream consumer demand, whichallows for infinitely variable flow to the downstream consumer due tothe nature of the modulating capability of the rotary plate valve 24.

Thus, the rotary plate valve system 10 enables the control of fluid flowthrough the outlet duct 22 with the plate 96, which is rotatable by theactuator 26 to vary a supply of fluid into the outlet duct 22. Therotation of the plate 96 to adjust the rotary plate valve 24 between thefirst, open position, the second, closed position and positionsin-between enables the use of a smaller actuator 26, thereby reducing aweight and a cost of the rotary plate valve system 10. Further, byproviding the first fluid channels 44.1-44.4, the openings 108.1-108.4and the second fluid channels 74.1-74.4 with the same flowpath area,flow and pressure loses through the rotary plate valve 24 are reducedwhen compared to a butterfly valve. In this example, the rotary platevalve 24 has half the pressure loss of a butterfly valve. In addition,the use of fillets and radiuses reduces flow separation as the fluidflows through the rotary plate valve 24. The use of the individual fluidchannels (the first fluid channels 44.1-44.4 and the second fluidchannels 74.1-74.4) provides for smooth transitions of fluid flowthrough the rotary plate valve 24 and minimizes areas of flow separationand re-circulation, thus, keeping the flow uniform and reducing thepressure losses. The rotary plate valve 24 leads to a simpler design,lower weight, smaller volume and allows for infinitely variablemodulated fluid flow to the downstream consumer. In addition, it shouldbe noted that while the second valve body 32 is shown coupled to theoutlet duct 22, the orientation of the rotary plate valve 24 may bereversed, such that the second valve body 32 is coupled to the bleedsupply inlet duct 14 and the first valve body 30 is coupled to theoutlet duct 22, depending upon the desired orientation of the actuator26.

It will be understood that the rotary plate valve system 10 describedwith regard to FIGS. 1-8D may be configured differently to providecontrol of the fluid flow into the outlet duct 22. In one example, withreference to FIG. 9, a rotary plate valve system 200 is shown. As therotary plate valve system 200 includes components that are substantiallysimilar to or the same as the rotary plate valve system 10 discussedwith regard to FIGS. 1-8D, the same reference numerals will be used todenote the same or similar features. Similar to the rotary plate valvesystem 10 of FIG. 1, the rotary plate valve system 200 is coupled to andin fluid communication with the bleed supply inlet duct 14 to receivebleed fluid, such as bleed air. The bleed air is selectively provided bythe rotary plate valve system 200 to other components or systemsassociated with the aircraft 20, such as the gas turbine engine 8, viathe at least one outlet duct 22. The rotary plate valve system 200includes a rotary plate valve 204 and the actuator 26. As discussed withregard to FIGS. 1-8D, the actuator 26 is responsive to one or morecontrol signals from the controller 28 associated with the APU 18 or theaircraft 20 to move the rotary plate valve 204 to a first, open position(in which bleed air flows through the outlet duct 202), a second, closedposition (in which bleed air does not flow through the outlet duct 202)and various positions in between the first, open position and the secondclosed position.

The rotary plate valve 204 includes a first valve body 210, a secondvalve body 212 and a plate assembly 214. The first valve body 210includes a first end 216 and an opposite second end 218. The first end216 is coupled to the bleed supply inlet duct 14 (FIG. 1) and the secondend 218 is coupled to the second valve body 212. With reference to FIG.10, the first end 216 includes a first flange 216.1 that is annular andsurrounds the first end 216 of the first valve body 210. The firstflange 216.1 defines a first counterbore 220 and second counterbore 222that each extend about a perimeter or circumference of the first flange216.1. The first counterbore 220 and the second counterbore 222 aredefined through the first flange 216.1 and cooperate to enable a portionof the bleed supply inlet duct 14 (FIG. 1) to be received within andfluidly coupled to the first valve body 210. It should be noted that theuse of the first counterbore 220 and the second counterbore 222 forcoupling the bleed supply inlet duct 14 (FIG. 1) to the rotary platevalve 204 is merely exemplary, as the first end 216 may include aplurality of threads, one or more flanges, etc.

The second end 218 defines a second annular flange 218.1. The secondannular flange 218.1 defines a third counterbore 224 that extends abouta perimeter or circumference of the second annular flange 218.1. Thethird counterbore 224 defines a recess within the second end 218 forreceiving a portion of the plate assembly 214. The second annular flange218.1 may be asymmetrical to define a gear housing portion 226. The gearhousing portion 226 extends outwardly from the exterior surface 210.1 ofthe first valve body 210. The gear housing portion 226 receives aportion of the plate assembly 214 to couple the plate assembly 214 tothe actuator 26.

The first valve body 210 also defines a fluid channel 230 within thefirst valve body 210 from the first end 216 to the second end 218. Inthis example, the first valve body 210 includes a single fluid channel230. The fluid channel 230 includes an inlet 222.1 defined by the secondcounterbore 222 and a first outlet 232. As will be discussed, the firstoutlet 232 is selectively in fluid communication with the second valvebody 212 based on a position of the plate assembly 214.

The second valve body 212 includes a third end 240 and an oppositefourth end 242. The third end 240 is coupled to the first valve body 210and the fourth end 242 is coupled to the outlet duct 22 (FIG. 1). Thethird end 240 defines a third annular flange 240.1. The third annularflange 240.1 defines a bearing groove 244 that extends about a perimeteror circumference of the third annular flange 240.1. The bearing groove244 is defined within a surface 240.2 of the third annular flange 240.1,and receives a portion of the plate assembly 214. The third end 240 mayalso define a second actuator housing portion 246. The second actuatorhousing portion 246 is substantially cylindrical, and extends outwardlyfrom an exterior surface 212.1 of the second valve body 212. The secondactuator housing portion 246 is hollow for receiving a portion of theactuator 26 to couple the actuator 26 to the rotary plate valve 204. Inone example, with reference to FIG. 9, the second actuator housingportion 246 includes a pair of flanges 247, which each define athroughbore 247.1. The flanges 247 receive a mechanical fastenertherethrough, such as a bolt, screw, etc. and cooperate with the matingflanges 124 of the actuator 26 to couple the actuator 26 to the rotaryplate valve 24.

The fourth end 242 includes a fourth flange 242.1 that is annular andsurrounds the fourth end 242 of the second valve body 212. The fourthflange 242.1 defines a fourth counterbore 248 and a fifth counterbore250 that each extend about a perimeter or circumference of the fourthflange 242.1. The fourth counterbore 248 and the fifth counterbore 250are defined through the fourth flange 242.1 and cooperate to enable aportion of the outlet duct 22 (FIG. 1) to be received within and fluidlycoupled to the fourth flange 242.1. It should be noted that the use ofthe fourth counterbore 248 and the fifth counterbore 250 for couplingthe outlet duct 22 (FIG. 1) to the rotary plate valve 204 is merelyexemplary, as the fourth end 242 may include a plurality of threads, oneor more flanges, etc. In this example, the fifth counterbore 250 definesa common second outlet 250.1 for the second valve body 212. The exteriorsurface 212.1 of the second valve body 212 is substantially smooth, andin one example, the exterior surface 32.1 tapers from the third end 240toward the fourth end 242. An interior surface 212.2 is opposite theexterior surface 212.1.

The second valve body 212 also defines an inlet flange 252 that extendsradially inward at the third end 240. In one example, the inlet flange252 defines a plurality of second inlets 254 that are spaced apart abouta perimeter or circumference of the inlet flange 252. In one example,the inlet flange 252 defines four second inlets 254.1-254.4. As will bediscussed, each of the second inlets 254.1-254.4 are selectively influid communication with the first valve body 210 based on a position ofthe plate assembly 214. The inlet flange 252 also defines a centralopening 256. The central opening 256 receives a portion of the plateassembly 214 to couple the plate assembly 214 to the second valve body212.

As the first valve body 210 and the second valve body 212 may be formedusing the same technique as the first valve body 30 and the second valvebody 32 as discussed with regard to FIGS. 1-8D, the formation of thefirst valve body 210 and the second valve body 212 will not be discussedin detail herein. Briefly, in one example, the first valve body 210 andthe second valve body 212 are composed of a metal or metal alloy.Generally, the first valve body 210 and the second valve body 212 arecomposed of aluminum alloys or steel alloys depending upon the operatingenvironment of the rotary plate valve 204. The first valve body 210 andthe second valve body 212 may be formed using investment casting,fugitive core casting, and using other additive manufacturing processes,including, but not limited to, direct metal laser sintering.

With continued reference to FIG. 10, the plate assembly 214 includes thecoupling member 90, a coupling flange 260, the bearing 94, a plate 262,the gear 98 and the second bearing ring 100. It should be noted thatwhile the plate assembly 214 is described and illustrated herein asincluding the bearing 94 and the second bearing ring 100, the plateassembly 214 may include one or more bushing rings, bushings, or otherdevices that enable rotation of the plate 262 relative to the firstvalve body 210 and the second valve body 212.

The coupling member 90 couples and retains the plate assembly 214 on thefirst valve body 210. In one example, the plurality of threads 90.1 ofthe coupling member 90 matingly engage with a plurality of threads 264.1of a shaft 264 of the plate 262 (FIG. 3). The coupling member 90 retainsthe bearing 94 and the plate 96 on the shaft 264 of the first valve body210. The coupling flange 260 is coupled to the inlet flange 252 andfurther retains the bearing 94 within the central opening 256 of theinlet flange 252. In one example, the coupling flange 260 may be coupledto the inlet flange 252 via one or more mechanical fasteners, such asscrews. The bearing 94 is received within a groove 264.2 of the shaft264 and is coupled to the plate 262. In one example, the inner race 94.1is coupled to the groove 264.2 on the shaft 264 and the outer race 94.2is coupled to the central opening 256 of the inlet flange 252. It shouldbe noted that the bearing 94 may also comprise a roller bearing, ifdesired.

The plate 262 is circular, and includes the first side 262.1 and anopposite second side 262.2. The first side 262.1 faces the second end218 of the first valve body 210. The second side 262.2 faces the inletflange 252 of the second valve body 212. With reference to FIG. 11, theplate 262 also defines the plurality of plate gear teeth 106, theplurality of openings 108 and the shaft 264 (FIG. 10). The plurality ofplate gear teeth 106 are defined along the perimeter or circumference ofthe plate 262. The plurality of plate gear teeth 106 meshingly engagewith the plurality of gear teeth 98.1 of the gear 98 to enable the plate262 to be driven or rotated by the actuator 26.

The plurality of openings 108 are defined through the plate 262 from thefirst side 262.1 to the second side 262.2. The plurality of openings 108are spaced apart about the perimeter or circumference of the plate 96.Generally, each of the plurality of openings 108 corresponds to one ofthe second inlets 254.1-254.4. Thus, in this example, the plate 262includes the four openings 108.1-108.4, which each have the sameflowpath area as the second inlets 254.1-254.4. The openings 108.1-108.4are sized such that the section 109.1-109.4 of the plate 96 betweenadjacent ones of the openings 108.1-108.4 is the same size as theadjacent opening 108.1-108.4. This provides for the second, closedposition of the rotary plate valve 204. Stated another way, the sections109.1-109.4 are sized to completely obstruct the flow of fluid into thesecond inlets 254.1-254.4, thereby providing the second, closed positionof the rotary plate valve 204. When the openings 108.1-108.4 are fullyor completely aligned with the second inlets 254.1-254.4, the rotaryplate valve 204 is in the first, open position such that fluid flowsfrom the first valve body 210 into and through the second inlets254.1-254.4.

With reference to FIG. 10, the shaft 264 extends axially from the secondside 262.2 of the plate 262 into the second valve body 212. The shaft264 is coupled to the bearing 94 such that the shaft 264 rotatablycouples the plate 262 to the second valve body 212. The plate 262 iscomposed of a metal or metal alloy, and may be cast, forged, stamped orformed with additive manufacturing, including, but not limited to,direct metal laser sintering.

The gear 98 is coupled to the actuator 26 and is driven by the actuator26 to move or drive the plate 262. The gear 98 is retained within thegear housing portion 226. The second bearing ring 100 facilitates therotation of the plate 262 relative to the second valve body 212. Theplurality of ball bearings 92.1 of the second bearing ring 100 arepositioned within the bearing groove 244 defined in the third end 240 ofthe second valve body 212.

The actuator 26 is in communication with the controller 28 (FIG. 1) toreceive one or more control signals to drive the gear 98, and thus, theplate 262 between the first, open position, the second, closed positionand positions in-between. The actuator 26 includes the motor 120 and theoutput shaft 122.

In one example, in order to assemble the rotary plate valve system 200,with the second valve body 212 formed and the second bearing ring 100formed and assembled, the second bearing ring 100 is positioned withinthe bearing groove 244 of the second valve body 212. The bearing 94 ispositioned within the central opening 256, and the coupling flange 260is fastened to the second valve body 212 to secure the bearing 94 to thesecond valve body 212. With the plate 262 formed, the shaft 264 ispositioned through the bearing 94 such that the shaft 264 is coupled tothe inner race 94.1 for rotation. The coupling member 90 is coupled tothe shaft 264 to couple the plate 262 to the second valve body 212. Withthe gear 98 formed, the gear 98 is positioned within the gear housingportion 226 of the first valve body 210 such that the plurality of gearteeth 98.1 mesh with the plurality of plate gear teeth 106 of the plate96. The output shaft 122 is inserted through the second actuator housingportion 246 of the second valve body 32 and is fixedly coupled to thegear 98, via a press-fit, for example. With the throughbores 126 of themating flanges 124 coaxially aligned with the throughbores 69.1 of theflanges 69 (FIG. 9) of the second actuator housing portion 246 of thesecond valve body 212, the mechanical fasteners are inserted to couplethe actuator 26 to the rotary plate valve 204.

With the rotary plate valve system 200 assembled, in the example of FIG.1, the bleed supply inlet duct 14 is coupled to the first end 216 of thefirst valve body 210, and the outlet duct 22 is coupled to the fourthend 242 of the second valve body 212. The actuator 26 is placed incommunication with the controller 28 via a communication architecturethat enables the transfer of commands, power, data, etc., such as a bus.As the control of the rotary plate valve 204 is the same as the controlof the rotary plate valve 24, the control of the rotary plate valve 204will not be discussed in detail herein. Briefly, based on the receipt ofone or more control signals from the controller 28, the motor 120 drivesthe output shaft 122 to rotate the gear 98 in a clockwise direction tomove the plate 262 and thus, the rotary plate valve 24 toward the first,open position. As the plate 262 moves relative to the second valve body212, the sections 109.1-109.4 obscure less of the second inlets254.1-254.4 as the rotary plate valve 24 approaches the 100% open orfirst, open position. In addition, based on the receipt of one or morecontrol signals from the controller 28, the motor 120 drives the outputshaft 122 to rotate the gear 98 in a counterclockwise direction to movethe plate 96 and thus, the rotary plate valve 24 toward the second,closed position. In the second, closed position, each of the secondinlets 254.1-254.4 is completely obstructed by the sections 109.1-109.4and the rotary plate valve 204 is 0% open. In the second, closedposition, the rotary plate valve 204 provides substantially zero fluidflow from the bleed supply inlet duct 14 to the outlet duct 22.

Thus, the rotary plate valve system 10 enables the control of fluid flowthrough the outlet duct 22 with the plate 262, which is rotatable by theactuator 26 to vary a supply of fluid into the outlet duct 22. Therotation of the plate 262 to adjust the rotary plate valve 24 betweenthe first, open position, the second, closed position and positionsin-between enables the use of a smaller actuator 26, thereby reducing aweight and a cost of the rotary plate valve system 10.

It will be understood that the rotary plate valve system 10 describedwith regard to FIGS. 1-8D may be configured differently to providecontrol of the fluid flow into the outlet duct 22. In one example, withreference to FIG. 12, a rotary plate valve system 300 is shown. As therotary plate valve system 300 includes components that are substantiallysimilar to or the same as the rotary plate valve system 10 discussedwith regard to FIGS. 1-8D, the same reference numerals will be used todenote the same or similar features. Similar to the rotary plate valvesystem 10 of FIG. 1, the rotary plate valve system 300 is coupled to andin fluid communication with the bleed supply inlet duct 14 (FIG. 1) toreceive bleed fluid, such as bleed air. The bleed air is selectivelyprovided by the rotary plate valve system 300 to other components orsystems associated with the aircraft 20, such as the gas turbine engine8 (FIG. 1), via at least one outlet duct 302. The rotary plate valvesystem 300 is also coupled to the bleed supply inlet duct 14 and the atleast one outlet duct 302 to enable surge fluid generated by the gasturbine engine 8 (FIG. 1) to pass through the rotary plate valve 304 andbe exhausted through the APU 18 (FIG. 1). The rotary plate valve system300 includes a rotary plate valve 304 and the actuator 26. As discussedwith regard to FIGS. 1-8D, the actuator 26 is responsive to one or morecontrol signals from the controller 28 (FIG. 1) to move the rotary platevalve 304 to a first, open bleed position (in which fluid flows throughthe at least one outlet duct 302), a second, closed position (in whichbleed air does not flow through the at least one outlet duct 302) andvarious bleed positions in between the first, open position and thesecond, closed position. The actuator 26 is also responsive to one ormore control signals from the controller 28 associated with the APU 18or the aircraft 20 (FIG. 1) to move the rotary plate valve 304 from thesecond, closed position to a first, open surge position to exhaustadditional flow generated by the gas turbine engine 8 (received from theat least one outlet duct 302) through the APU 18.

With reference to FIG. 12, the at least one outlet duct 302 includes aplurality of load outlet ducts 306 and a plurality of surge ducts 308.Each of the plurality of load outlet ducts 306 and the plurality ofsurge ducts 308 are coupled to the rotary plate valve 304 via an outletflange 310. In this example, the plurality of load outlet ducts 306include four load outlet ducts 306.1-306.4, which each have a respectiveload inlet 312.1-312.4 coupled to and in fluid communication with theoutlet flange 310 and a respective load outlet 314.1-314.4 coupled toand in fluid communication with a downstream consumer via a load outletflange 316. The load outlet flange 316 defines a common load outlet, andcan be coupled to or in fluid communication with a downstream consumer,such as the gas turbine engine 8 (FIG. 1). The load outlet flange 316includes a first end 316.1 having a plurality of flow inlets, and asecond end 316.2 that defines the common load outlet. The plurality ofsurge ducts 308 include four surge ducts 308.1-308.4, which each have arespective surge outlet 318.1-318.4 coupled to and in fluidcommunication with the outlet flange 310 and a respective surge inlet320.1-320.4 coupled to and in fluid communication with the gas turbineengine 8 (FIG. 1) via a surge inlet flange 322. The surge inlet flange322 defines a common surge inlet, and can be coupled to or in fluidcommunication with the gas turbine engine 8 to enable surge fluid flowfrom the gas turbine engine 8 to flow through the rotary plate valve 304and be exhausted through the APU 18 (FIG. 1). The surge inlet flange 322includes a first end 322.1 having a plurality of flow outlets, and asecond end 322.2 that defines the common surge inlet.

With reference to FIG. 13, the outlet flange 310 is shown in greaterdetail. In this example, the outlet flange 310 includes a plurality offlow channels 324 defined within the outlet flange 310 about acircumference of the outlet flange 310. In this example, the outletflange 310 includes eight flow channels 324.1-324.8, which are separatedor defined by inner walls of the outlet flange 310. Each of the flowchannels 324.1-324.8 has a respective inlet 326.1-326.8 at a first endof the outlet flange 310, which is in fluid communication with the firstcommon inlet 42.1 of the rotary plate valve 304. The flow channels324.1-324.8 separate downstream from the inlets 326.1-326.8 such thatrespective outlets 328.1-328.8 are spaced apart from each other aboutthe outlet flange 310 to facilitate coupling the plurality of loadoutlet ducts 306 and the plurality of surge ducts 308 to the respectiveoutlets 328.1-328.8. The outlets 328.1-328.8 are coupled to therespective ones of the load outlet ducts 306 and the surge ducts 308 soas to be in selective fluid communication with the respective one of theload outlet ducts 306 and the surge ducts 308 based on a position of therotary plate valve 304.

With reference to FIG. 12, the rotary plate valve 304 includes a firstvalve body 330, a second valve body 332 and a plate assembly 334. Thefirst valve body 330 includes the first end 36 and the opposite secondend 38. In this example, the first end 36 is coupled to the outletflange 310 and the second end 38 is coupled to the second valve body 32.With reference to FIG. 14, the first end 36 includes the first flange36.1 that enables a portion of the outlet flange 310 to be receivedwithin and fluidly coupled to the first valve body 330. The first end 36also defines the common first inlet 42.1 for each of a first pluralityof fluid channels 344 defined in the first valve body 330 from the firstend 36 to the second end 38. The first valve body 330 has an interiorsurface 330.2 that is opposite an exterior surface 330.1. The second end38 defines the second annular flange 38.1 and the gear housing portion49 (FIG. 12).

With reference to FIG. 13, the first plurality of fluid channels 344 isdefined within the first valve body 330 from the first end 36 to thesecond end 38. In this example, the first valve body 330 includes eightfirst fluid channels 344.1-344.8. Each of the first fluid channels344.1-344.8 are spaced apart about a perimeter or circumference of thefirst valve body 330. Each of the first fluid channels 344.1-344.8includes the common first inlet 42.1 and a respective first outlet350.1-350.8 (FIG. 14). As will be discussed, each of the first outlets350.1-350.8 are selectively in fluid communication with the second valvebody 32 based on a position of the plate assembly 334.

With reference to FIG. 13A, each pair of the first fluid channels344.1-344.8 (344.2, 344.3; 344.4, 344.5; 344.6, 344.7; 344.8, 344.1)generally corresponds to one of the first fluid channels 44.1-44.4 ofthe first valve body 30 of FIGS. 1-8D. In this regard, each pair of thefirst fluid channels 344.1-344.8 is defined by one of the sidewalls52.1, 52.2, the conical flange 52.3, a divider 352 and the interiorsurface 330.2. The sidewalls 52.1, 52.2 of adjacent pairs of the firstfluid channels 44.1-44.4 are interconnected via the rib 52.4. Generally,the sidewalls 52.1, 52.2 cooperate to form a substantially triangularshape that extends from the first end 36 to the conical flange 52.3, andthe divider 352 is positioned between the sidewalls 52.1, 52.2 toseparate the respective pair of fluid channels (344.2, 344.3; 344.4,344.5; 344.6, 344.7; 344.8, 344.1) into two separate flow channels. Inone example, the sidewalls 52.1, 52.2 and the divider 352 are coupled tothe conical flange 52.3 downstream from the common first inlet 42.1. Inthis example, with reference to FIG. 14, the sidewalls 52.1, 52.2 andthe divider 352 form the common wall 53 that extends along a length ofthe first valve body 330 from the common first inlet 42.1 to thedivergence point 54 defined at the conical flange 52.3. Generally, thedivergence point 54 may be located between the common first inlet 42.1and any location downstream of common first inlet 42.1 within the firstvalve body 330 based on the specific installation environment of therotary plate valve 304. By diverging at the divergence point 54 definedby the conical flange 52.3, the first fluid channels 344.1-344.8 alsoenable a portion of the plate assembly 334 to be received within thesecond end 38 of the first valve body 330. In this regard, the conicalflange 52.3 defines the first cavity 56 within the second end 38 of thefirst valve body 330.

The first fluid channels 344.1-344.8 diverge outwardly or away from alongitudinal axis L defined through the rotary plate valve 304. Each ofthe first fluid channels 344.1-344.8 are bounded by one of the sidewalls52.1, 52.2, the divider 352 and the interior surface 30.2 such that, inthe example of the rotary plate valve 304 as a surge valve, downstreamfrom the common inlet 42.1, each of the first fluid channels 344.1-344.8is fluidly isolated from or separate from a remainder of the first fluidchannels 344.1-344.8. Stated another way, in the example of the rotaryplate valve 304 as a surge valve with surge fluid flowing in thedirection of Fs, the first fluid channels 344.1-344.8 define discretefluid channels downstream from the common inlet 42.1 such that fluiddownstream from the common inlet 42.1 does not mix between the firstfluid flow channels 344.1-344.8. In this example, the first outlets350.1-350.8 are defined at the second end 38 of the first valve body330. Generally, each of the first outlets 350.1-350.8 is discrete, suchthat fluid flowing through the respective first fluid channels344.1-344.8 enters or exits the respective first fluid channel344.1-344.8 at the respective first outlet 350.1-350.8. Each of thefirst outlets 350.1-350.8 is selectively in fluid communication withrespective ones of a second plurality of fluid channels 374 defined inthe second valve body 332 based on a position of the plate assembly 334.

The second valve body 332 includes the third end 60 and the oppositefourth end 62. The third end 60 is coupled to the first valve body 330and the fourth end 62 is coupled to the bleed supply inlet duct 14 (FIG.1). With reference to FIG. 13, the third end 60 defines the thirdannular flange 60.1 and the second actuator housing portion 68. Thefourth end 62 includes the fourth flange 62.1 that cooperates to enablea portion of the bleed supply inlet duct 14 (FIG. 1) to be receivedwithin and fluidly coupled to the fourth flange 62.1. In this example,with reference to FIG. 14, the fourth flange 62.1 defines the commonsecond outlet 72.1 for each of a second plurality of fluid channels 374defined in the second valve body 332 from the third end 60 to the fourthend 62. The second valve body 332 has an interior surface 332.2 that isopposite an exterior surface 332.1.

The second plurality of fluid channels 374 is defined within the secondvalve body 332 from the third end 60 to the fourth end 62. In thisexample, with reference to FIG. 15, the second valve body 332 includeseight second fluid channels 374.1-374.8, which each correspond to one ofthe first fluid channels 344.1-344.8. Each of the second fluid channels374.1-374.8 are spaced apart about a perimeter or circumference of thesecond valve body 332. In the example of the rotary plate valve 304 as asurge valve with surge fluid flowing in the direction of Fs, each of thesecond fluid channels 374.1-374.8 includes a respective second inlet376.1-376.8 and the common second outlet 72.1. As will be discussed,each of the second inlets 376.1-376.8 are selectively in fluidcommunication with the first valve body 330 based on a position of theplate assembly 334. In this regard, a sub-plurality of the second fluidchannels (376.1, 376.3, 376.5, 376.7) are in selective fluidcommunication with a sub-plurality of the first fluid channels (344.1,344.3, 344.5, 344.7) based on a position of the plate assembly 334, anda sub-plurality of the second fluid channels (376.2, 376.4, 376.6,376.8) are in selective fluid communication with a sub-plurality of thefirst fluid channels (344.2, 344.4, 344.6, 344.8) based on a position ofthe plate assembly 334.

Each pair of the second fluid channels 374.1-374.8 (374.2, 374.3; 374.4,374.5; 374.6, 374.7; 374.8, 374.1) generally corresponds to one of thesecond fluid channels 74.1-74.4 of the second valve body 32 of FIGS.1-8D. In this regard, each of the second fluid channels 374.1-374.8 isdefined by one of the pair of sidewalls 78.1, 78.2, the second conicalflange 78.3, a divider 378 and the interior surface 332.2. The sidewalls78.1, 78.2 of adjacent ones of the second fluid channels 374.1-374.8 areinterconnected via the rib 78.4. Generally, the sidewalls 78.1, 78.2 andthe divider 378 cooperate to form a substantially triangular shape thatextends from the second conical flange 78.3 to the fourth end 62. In oneexample, the sidewalls 78.1, 78.2 and the divider 378 are coupled to thesecond conical flange 78.3 at the third end 60 to define the secondinlets 376.1-376.8. In this example, with reference to FIG. 14, thesecond conical flange 78.3 includes the shaft 79 defined internallywithin the second valve body 332. The shaft 79 receives and is coupledto a portion of the plate assembly 334.

In the example of the rotary plate valve 304 as a surge valve with surgefluid flowing in the direction of Fs, the sidewalls 78.1, 78.2downstream from the second conical flange 78.3 form the second commonwall 80 that extends along a length from the convergence point 82defined at the second conical flange 78.3 to the common second outlet72.1. The convergence point 82 is selected to provide reduced fluid andpressure losses as the fluid flows through the second valve body 332.Generally, the convergence point 82 may be located between the commonsecond outlet 72.1 and any location upstream of common second outlet72.1 within the second valve body 332 based on the specific installationenvironment of the rotary plate valve 304. By diverging prior to theconvergence point 82, the second fluid channels 374.1-374.8 also enablea portion of the plate assembly 334 to be received within the third end60 of the second valve body 332. In this regard, the second conicalflange 78.3 defines the second cavity 84 that cooperates with the firstcavity 56 of the first valve body 330 to receive a portion of the plateassembly 334.

Generally, the second fluid channels 374.1-374.8 diverge outwardly oraway from the longitudinal axis L defined through the rotary plate valve304 prior to converging at the convergence point 82. Each of the secondfluid channels 74.1-74.4 are bounded by one of the sidewalls 78.1, 78.2,the divider 378 and the interior surface 332.2 such that, in the exampleof the rotary plate valve 304 as a surge valve with surge fluid flowingin the direction of Fs, upstream from the common second outlet 72.1,each of the second fluid channels 374.1-374.8 is fluidly isolated fromor separate from a remainder of the second fluid channels 374.1-374.8.Stated another way, with surge fluid flowing in the direction of Fs, thesecond fluid channels 374.1-374.8 define discrete fluid channelsupstream from the common second outlet 72.1 such that fluid upstreamfrom the common second outlet 72.1 does not mix between the second fluidchannels 374.1-374.8. In this example, the second inlet 376.1-376.8 isdefined at the third end 60 of the second valve body 32. Generally, eachof the second inlets 376.1-376.8 is discrete, such that fluid flowingthrough the respective second fluid channels 374.1-374.8 enters or exitsthe respective second fluid channels 374.1-374.8 at the respectivesecond inlet 376.1-376.8. Each of the second inlets 376.1-376.8 isselectively in fluid communication with respective ones of the firstoutlets 350.1-350.8 defined in the first valve body 330 such that fluidfrom a respective one of the first fluid channels 344.1-344.8 flows intoa respective one of the second fluid channels 374.1-374.8 based on aposition of the plate assembly 334.

In one example, each of the first fluid channels 344.1-344.8 and thesecond fluid channels 374.1-374.8 have the same flowpath area. Byproviding the first fluid channels 344.1-344.8 and the second fluidchannels 374.1-374.8 with the same flowpath area, flow and pressurelosses are reduced as the fluid flows from the first fluid channels344.1-344.8 into the second fluid channels 374.1-374.8. In addition,each of the sidewalls 52.1, 52.2; 78.1, 78.2 and the dividers 352, 378include fillets along the interconnection of the respective sidewalls52.1, 52.2; 78.1, 78.2 and dividers 352, 378, which reduces flowseparation through each of the first fluid channels 344.1-344.8 and thesecond fluid channels 374.1-374.8. In addition, each leading edge of thesidewalls 52.1, 52.2 and the dividers 352 has a radius to provide for asmooth transition into the respective first fluid channel 344.1-344.8from the common first inlet 42.1 to reduce flow losses. Further, eachleading edge of the sidewalls 78.1, 78.2 and the dividers 378 has aradius to provide for a smooth transition into the respective secondfluid channel 374.1-374.8 from the plate 96, thereby reducing flowlosses.

In one example, each of the first fluid channels 344.1-344.8 and thesecond fluid channels 374.1-374.8 is integrally formed, monolithic orone-piece with the first valve body 330 and the second valve body 332,respectively. In this example, the first valve body 330 and the secondvalve body 332 are composed of and formed in the same manner as thefirst valve body 30 and the second valve body 32 as discussed withregard to FIGS. 1-8D, and thus, the composition and the method ofmanufacturing the first valve body 330 and the second valve body 332will not be discussed in detail herein. Briefly, however, the firstvalve body 330 and the second valve body 332 are composed of a metal ormetal alloy, and are formed using additive manufacturing.

With reference to FIG. 13, the plate assembly 334 is shown expanded fromthe first valve body 330 and the second valve body 332. In one example,the plate assembly 334 includes the coupling member 90, the firstbearing ring 92, the bearing 94, a plate 396, the gear 98 and the secondbearing ring 100. It should be noted that while plate assembly 334 isdescribed and illustrated herein as including the first bearing ring 92,the bearing 94 and the second bearing ring 100, the plate assembly 334may include one or more bushing rings, bushings, or other devices thatenable rotation of the plate 396 relative to the first valve body 330and the second valve body 332.

The coupling member 90 couples and retains the plate assembly 334 on thesecond valve body 332. The first bearing ring 92 facilitates therotation of the plate 396 relative to the first valve body 330. Thebearing 94 is received within the groove 79.2 of the shaft 79 and iscoupled to the plate 396. The plate 396 is circular, and includes afirst side 396.1 and an opposite second side 396.2. The plate 396 iscoupled between the first valve body 330 and the second valve body 332.The first side 396.1 includes the first plate bearing groove 102 definedabout a majority of a perimeter or circumference of the first side396.1, and faces the second end 38 of the first valve body 330. Thesecond side 396.2 includes the second plate bearing groove 104 definedabout a majority of a perimeter or circumference of the second side396.2, and faces the third end 60 of the second valve body 332. In thisregard, with reference to FIG. 16, the plate 396 also defines aplurality of plate gear teeth 398, a plurality of openings 408 and thecentral opening 110. The plurality of plate gear teeth 398 are definedalong the perimeter or circumference of the plate 396 and interrupt thefirst plate bearing groove 102 and the second plate bearing groove 104.The plurality of plate gear teeth 398 meshingly engage with the gear 98to enable the plate 396 to be driven or rotated by the actuator 26.Generally, the plurality of plate gear teeth 398 extend along theperimeter of the plate 396 for a predetermined arc length that allowsfor the correct timing of the rotation of the plate 396 and allows forthe predetermined rotational angle needed to open each of the secondfluid channels 374.1-374.8. Generally, the arc length is predeterminedbased on the number of flow paths incorporated into the rotary platevalve 304. In one example, the plurality of gear teeth 398 of the plate396 has a greater number of teeth than the plurality of gear teeth 106of the plate 96 in order to rotate the plate 396 to open each of thesecond fluid channels 374.1-374.8.

The plurality of openings 408 are defined through the plate 396 from thefirst side 396.1 to the second side 396.2. The plurality of openings 408are spaced apart about the perimeter or circumference of the plate 396.Generally, each of the plurality of openings 408 corresponds to one ofthe first fluid channels 344.1-344.8 and one of the second fluidchannels 374.1-374.8. Thus, in this example, the plate 396 includeseight openings 408.1-408.8, which each have the same flowpath area asthe first fluid channels 344.1-344.8 and the second fluid channels374.1-374.8. The openings 408.1-408.8 are sized such that the section109.1-109.4 of the plate 396 between adjacent pairs of the openings408.1-408.8 is the same size as the pair of adjacent openings408.1-408.8. This provides for the second, closed position of the rotaryplate valve 304. Stated another way, the sections 109.1-109.4 are sizedto completely obstruct the flow of fluid between the first fluidchannels 344.1-344.8 and the second fluid channels 374.1-374.8, therebyproviding the second, closed position of the rotary plate valve 304.

The openings 408.1-408.8 are shaped to correspond with the shape of thefirst outlets 350.1-350.8 and the second inlets 376.1-376.8. In oneexample, each of the openings 408.1-408.8 is defined by the first arcsegment 112, the opposite second arc segment 114, the pair of radialsegments 116.1, 116.2 and a dividing radial segment 416. The dividingradial segment separates each pair of openings 408.1-408.8.

With reference to FIG. 13, the central opening 110 includes the flange110.1 that couples the plate 396 to the bearing 94. The plate 396 iscomposed of a metal or metal alloy, and may be cast, forged, stamped orformed with additive manufacturing, including, but not limited to,direct metal laser sintering. The gear 98 is coupled to the actuator 26and is driven by the actuator 26 to move or drive the plate 396. Thegear 98 includes the plurality of gear teeth 98.1 defined about theperimeter or circumference of the gear 98 that meshingly engage with theplurality of plate gear teeth 106 of the plate 396 to move or drive theplate 396. The second bearing ring 100 facilitates the rotation of theplate 396 relative to the second valve body 332.

The rotary plate valve 304 movable between the various positions withthe actuator 26, which is in communication with the controller 28.Generally, the actuator 26 is in communication with the controller 28(FIG. 12) to receive one or more control signals to drive the gear 98,and thus, the plate 396 between the first, open position, the second,closed position and positions in-between. The controller 28 includes atleast one processor 130 and the computer readable storage device ormedia 132 (FIG. 1). The computer-readable storage device or media 132stores data, some of which represent executable instructions, used bythe controller 28 in controlling components associated with the rotaryplate valve system 300. The instructions may include one or moreseparate programs, each of which comprises an ordered listing ofexecutable instructions for implementing logical functions. Theinstructions, when executed by the processor 130, receive and processinput signals, perform logic, calculations, methods and/or algorithmsfor controlling the components of the rotary plate valve system 300 ofthe aircraft 12, and generate control signals to the actuator 26 of therotary plate valve system 300 to control a position of the plate 396based on the logic, calculations, methods, and/or algorithms. Althoughonly one controller 28 is shown in FIG. 12, embodiments of the aircraft12 may include any number of controllers 28 that communicate over anysuitable communication medium or a combination of communication mediumsand that cooperate to process the sensor signals, perform logic,calculations, methods, and/or algorithms, and generate control signalsto control features of the rotary plate valve system 300.

In various embodiments, one or more instructions of the controller 28are associated with the rotary plate valve system 300 and, when executedby the processor 130 (FIG. 1), the instructions output one or morecontrol signals to the actuator 26 to move the plate 396, and thus, therotary plate valve 304 between the first, open load position, thesecond, closed position and positions in-between. In addition, theinstructions output one or more control signals to the actuator 26 tomove the plate 396, and thus, the rotary plate valve 304 between thefirst, open surge position and the second, closed position. In variousembodiments, a rotary valve control system may include one or morecontrol modules embedded within the controller 28 for controlling theactuator 26. The rotary valve control system may include a closed or anopen loop control methodology that controls the actuator 26 to move theplate 396 to a predetermined position based on input signals receivedfrom various sensors or systems associated with the aircraft 12, or inother embodiments, the rotary valve control system may be an internalopen loop control system that controls the actuator 26 based on inputreceived to the rotary valve control system. In certain embodiments, therotary valve control system may comprise a combination of the two. Dueto the nature and capability of the rotating plate 396, the actuator 26can be used to modulate the position of the plate 396 such that amodulated fluid flow results from the exit of the rotary plate valve 24.The actuator 26 can also be used to enable surge flow from the gasturbine engine 8 (FIG. 1) to be exhausted through the APU 18 (FIG. 1).

As the method of assembly of the rotary plate valve 304 is the same asthe rotary plate valve 24 discussed with regard to FIGS. 1-8D, theassembly of the rotary plate valve 304 will not be discussed in detailherein. With the rotary plate valve 304 assembled, the output shaft 122is inserted through the second actuator housing portion 68 of the secondvalve body 32 and is fixedly coupled to the gear 98, via a press-fit,for example. With the throughbores 126 of the mating flanges 124coaxially aligned with the throughbores 69.1 of the flanges 69 of thesecond actuator housing portion 68 of the second valve body 332, themechanical fasteners are inserted to couple the actuator 26 to therotary plate valve 304.

With the rotary plate valve system 300 assembled, with reference to FIG.12, the bleed supply inlet duct 14 is coupled to the fourth end 62 ofthe second valve body 332, and the outlet flange 310 is coupled to thefirst end 36 of the first valve body 330. The plurality of load outletducts 306 are coupled to the outlet flange 310 and to the load outletflange 316. The plurality of surge ducts 308 are coupled to the outletflange 310 and to the surge inlet flange 322. The actuator 26 is placedin communication with the controller 28 via a communication architecturethat enables the transfer of commands, power, data, etc., such as a bus.Initially, the rotary plate valve system 300 is in the second, closedposition, as shown in FIG. 17.

Based on the receipt of one or more control signals from the controller28 to operate the rotary plate valve 304 as a surge valve, the motor 120drives the output shaft 122 to rotate the gear 98 (FIG. 13) in aclockwise direction to move the plate 396 and thus, the rotary platevalve 304 toward the first, open surge position (100% open for surgeflow). In one example, upon receipt of one or more control signals tomove the rotary plate valve 304 to the first, open surge position, withreference to FIG. 17A, the actuator 26 rotates the gear 98 (FIG. 13)clockwise for a predetermined rotational angle that corresponds to amovement of the plate 396 that results in about a 100% blockage orobstruction of flow through the respective second inlets 376.2, 376.4,376.6, 376.8 that are associated with the load outlet ducts 306.1-306.4,while the respective second inlets 376.1, 376.3, 376.5, 376.7 are about0% unobstructed and are in full fluid communication with the respectivefirst fluid channels 344.1, 344.3, 344.5, 344.7 and the bleed supplyinlet duct 14 (FIG. 13) to direct the surge flow from the gas turbineengine 8 into the APU 18 (FIG. 1). Stated another way, the actuator 26rotates the gear 98 clockwise to move the plate 396 such that thesections 109.1-109.4 obscure or cover about 100% of each of therespective second inlets 376.2, 376.4, 376.6, 376.8, as shown in FIG.17A, which inhibits or prevents a flow of fluid into the load outletducts 306.1-306.4, while the second inlets 376.1, 376.3, 376.5, 376.7remain fully open to enable the surge flow from the gas turbine engine 8to flow into the APU 18 (FIG. 1). Thus, in the first, open surgeposition, the plate 396 provides full fluid flow from the gas turbineengine 8 to the APU 18 (FIG. 1).

When the rotary plate valve 304 is a load valve, the rotary plate valve304 is initially in the second, closed position as shown in FIG. 17.Based on the receipt of one or more control signals from the controller28 to operate the rotary plate valve 304 as a load valve to provideabout a 25% modulated flow, for example, the motor 120 drives the outputshaft 122 to rotate the gear 98 (FIG. 13) in a clockwise direction tomove the plate 396 and thus, the rotary plate valve 304 toward the about25% open position. In one example, upon receipt of one or more controlsignals to move the rotary plate valve 304 to provide about a 25%modulated flow, with reference to FIG. 17B, the actuator 26 rotates thegear 98 (FIG. 13) clockwise for a predetermined rotational angle thatcorresponds to a movement of the plate 396 that results in about a 100%blockage or obstruction of flow through the second inlets 376.1, 376.3,376.5, 376.7 that are associated with the surge ducts 308.1-308.4, whilethe second inlets 376.2, 376.4, 376.6, 376.8 are about 75% blocked orobstructed by the sections 109.1-109.4. Stated another way, the actuator26 rotates the gear 98 clockwise to move the plate 396 such that thesections 109.1-109.4 obscure or cover about 100% of each of the secondinlets 376.1, 376.3, 376.5, 376.7 and obscure or cover about 75% of eachof the second inlets 376.2, 376.4, 376.6, 376.8, as shown in FIG. 17B,which inhibits or prevents a flow of fluid into the surge ducts308.1-308.4, while the second inlets 376.2, 376.4, 376.6, 376.8 remainabout 25% open to enable the modulated load flow from the APU 18 to flowthrough the load outlet ducts 306.1-306.4 to a downstream consumer, suchas the gas turbine engine 8 (FIG. 1).

When the rotary plate valve 304 is a load valve, in another example,based on the receipt of one or more control signals from the controller28 to operate the rotary plate valve 304 as a load valve to provideabout a 50% modulated flow, for example, the motor 120 drives the outputshaft 122 to rotate the gear 98 (FIG. 13) in a clockwise direction tomove the plate 396 and thus, the rotary plate valve 304 toward the about50% open position. In one example, upon receipt of one or more controlsignals to move the rotary plate valve 304 to provide about a 50%modulated flow, with reference to FIG. 17C, the actuator 26 rotates thegear 98 (FIG. 13) clockwise for a predetermined rotational angle thatcorresponds to a movement of the plate 396 that results in about a 100%blockage or obstruction of flow through the second inlets 376.1, 376.3,376.5, 376.7 that are associated with the surge ducts 308.1-308.4, whilethe second inlets 376.2, 376.4, 376.6, 376.8 are about 50% blocked orobstructed by the sections 109.1-109.4. Stated another way, the actuator26 rotates the gear 98 clockwise to move the plate 396 such that thesections 109.1-109.4 obscure or cover about 100% of each of the secondinlets 376.1, 376.3, 376.5, 376.7 and obscure or cover about 50% of eachof the second inlets 376.2, 376.4, 376.6, 376.8, as shown in FIG. 17C,which inhibits or prevents a flow of fluid into the surge ducts308.1-308.4, while the second inlets 376.2, 376.4, 376.6, 376.8 remainabout 50% open to enable the modulated load flow from the APU 18 to flowthrough the load outlet ducts 306.1-306.4 to a downstream consumer, suchas the gas turbine engine 8 (FIG. 1).

When the rotary plate valve 304 is a load valve, in another example,based on the receipt of one or more control signals from the controller28 to operate the rotary plate valve 304 as a load valve to provideabout a 75% modulated flow, for example, the motor 120 drives the outputshaft 122 to rotate the gear 98 (FIG. 13) in a clockwise direction tomove the plate 396 and thus, the rotary plate valve 304 toward the about75% open position. In one example, upon receipt of one or more controlsignals to move the rotary plate valve 304 to provide about a 75%modulated flow, with reference to FIG. 17D, the actuator 26 rotates thegear 98 (FIG. 13) clockwise for a predetermined rotational angle thatcorresponds to a movement of the plate 396 that results in about a 100%blockage or obstruction of flow through the second inlets 376.1, 376.3,376.5, 376.7 that are associated with the surge ducts 308.1-308.4, whilethe second inlets 376.2, 376.4, 376.6, 376.8 are about 25% blocked orobstructed by the sections 109.1-109.4. Stated another way, the actuator26 rotates the gear 98 clockwise to move the plate 396 such that thesections 109.1-109.4 obscure or cover about 100% of each of the secondinlets 376.1, 376.3, 376.5, 376.7 and obscure or cover about 25% of eachof the second inlets 376.2, 376.4, 376.6, 376.8, as shown in FIG. 17D,which inhibits or prevents a flow of fluid into the surge ducts308.1-308.4, while the second inlets 376.2, 376.4, 376.6, 376.8 remainabout 75% open to enable the modulated load flow from the APU 18 to flowthrough the load outlet ducts 306.1-306.4 to a downstream consumer, suchas the gas turbine engine 8 (FIG. 1).

When the rotary plate valve 304 is a load valve, in another example,based on the receipt of one or more control signals from the controller28 to operate the rotary plate valve 304 as a load valve to provideabout a 100% or full load flow, for example, the motor 120 drives theoutput shaft 122 to rotate the gear 98 (FIG. 13) in a clockwisedirection to move the plate 396 and thus, the rotary plate valve 304toward the about 100% open position (third, open load position). In oneexample, upon receipt of one or more control signals to move the rotaryplate valve 304 to provide about a 100% full load flow, with referenceto FIG. 17E, the actuator 26 rotates the gear 98 (FIG. 13) clockwise fora predetermined rotational angle that corresponds to a movement of theplate 396 that results in about a 100% blockage or obstruction of flowthrough the second inlets 376.1, 376.3, 376.5, 376.7 that are associatedwith the surge ducts 308.1-308.4, while the second inlets 376.2, 376.4,376.6, 376.8 are about 0% blocked or obstructed by the sections109.1-109.4. Stated another way, the actuator 26 rotates the gear 98clockwise to move the plate 396 such that the sections 109.1-109.4obscure or cover about 100% of each of the second inlets 376.1, 376.3,376.5, 376.7 and obscure or cover about 0% of each of the second inlets376.2, 376.4, 376.6, 376.8, as shown in FIG. 17E, which inhibits orprevents a flow of fluid into the surge ducts 308.1-308.4, while thesecond inlets 376.2, 376.4, 376.6, 376.8 are fully open to enable fullload fluid flow from the APU 18 to flow through the load outlet ducts306.1-306.4 to a downstream consumer, such as the gas turbine engine 8(FIG. 1).

In addition, based on the receipt of one or more control signals fromthe controller 28, the motor 120 drives the output shaft 122 to rotatethe gear 98 (FIG. 13) in a counterclockwise direction to move the plate396 and thus, the rotary plate valve 304 toward the second, closedposition. In the second, closed position, each of the second inlets376.1-376.8 is completely obstructed by the sections 109.1-109.4 suchthat no fluid flows from the first outlets 350.1-350.8 to the secondinlets 376.1-376.8, and the rotary plate valve 304 is 0% open (FIG. 17).In the second, closed position, the rotary plate valve 304 providessubstantially zero fluid flow between the bleed supply inlet duct 14 andthe at least one outlet duct 302. It should be noted that the clockwisemovement of the gear 98 described herein is merely exemplary, as thegear 98 may also be configured to move in a counterclockwise directionto move the plate 396 to the selected position. Moreover, it should beunderstood that when the rotary plate valve 304 is a load valve, theplate 296 is actively movable by the actuator 26 via the controller 28to any position between the second, closed position (FIG. 17) and thefirst, open position (FIG. 17E) based on a downstream consumer demand,which allows for infinitely variable flow to the downstream consumer dueto the nature of the modulating capability of the rotary plate valve304.

Thus, the rotary plate valve system 300 enables the control of fluidflow through the at least one outlet duct 202 and the bleed supply inletduct 14 with the plate 396, which is rotatable by the actuator 26 tovary a supply of fluid into and out of the at least one outlet duct 202.When used as a load valve, the rotation of the plate 396 to adjust therotary plate valve 304 between the first, open position, the second,closed position and positions in-between enables the use of a smalleractuator 26, thereby reducing a weight and a cost of the rotary platevalve system 300. Further, by providing the first fluid channels344.1-344.8, the openings 408.1-408.8 and the second fluid channels374.1-374.8 with the same flowpath area, flow and pressure loses throughthe rotary plate valve 304 are reduced when compared to a butterflyvalve. Moreover, the rotary plate valve 304 incorporates two differentvalve functions (load and surge) into a single valve, which reduces partcost, weight and cost. In addition, the use of fillets and radiusesreduces flow separation as the fluid flows through the rotary platevalve 304. The use of the individual fluid channels (the first fluidchannels 344.1-344.8 and the second fluid channels 374.1-374.8) providesfor smooth transitions of fluid flow through the rotary plate valve 304and minimizes areas of flow separation and re-circulation, thus, keepingthe flow uniform and reducing the pressure losses. The rotary platevalve 304 leads to a simpler design, lower weight, smaller volume,higher reliability and allows for infinitely variable modulated fluidflow to the downstream consumer. In addition, it should be noted thatwhile the rotary plate valve system 300 is shown and described herein asincluding four load outlet ducts 306 and four surge ducts 308, therotary plate valve system 300 may be employed with any number of loadoutlet ducts 306 and surge ducts 308.

In this document, relational terms such as first and second, and thelike may be used solely to distinguish one entity or action from anotherentity or action without necessarily requiring or implying any actualsuch relationship or order between such entities or actions. Numericalordinals such as “first,” “second,” “third,” etc. simply denotedifferent singles of a plurality and do not imply any order or sequenceunless specifically defined by the claim language. The sequence of thetext in any of the claims does not imply that process steps must beperformed in a temporal or logical order according to such sequenceunless it is specifically defined by the language of the claim. Theprocess steps may be interchanged in any order without departing fromthe scope of the invention as long as such an interchange does notcontradict the claim language and is not logically nonsensical.

While at least one exemplary embodiment has been presented in theforegoing detailed description, it should be appreciated that a vastnumber of variations exist. It should also be appreciated that theexemplary embodiment or exemplary embodiments are only examples, and arenot intended to limit the scope, applicability, or configuration of thedisclosure in any way. Rather, the foregoing detailed description willprovide those skilled in the art with a convenient road map forimplementing the exemplary embodiment or exemplary embodiments. Itshould be understood that various changes can be made in the functionand arrangement of elements without departing from the scope of thedisclosure as set forth in the appended claims and the legal equivalentsthereof.

What is claimed is:
 1. A rotary valve system, comprising: a first valvebody having a first plurality of fluid channels, each one of the firstplurality of fluid channels having a common first inlet to receive afluid and a first outlet; a second valve body coupled to the first valvebody, the second valve body having a second plurality of fluid channels,each one of the second plurality of fluid channels having a second inletand a second outlet; and a plate assembly including a plate coupledbetween the first valve body and the second valve body, the platedefining a plurality of openings, the plate movable between at least afirst, open position in which the first outlet of at least one of thefirst plurality of fluid channels is in fluid communication with thesecond inlet of at least one of the second plurality of fluid channelsand a second, closed position in which the second inlet of each of thesecond plurality of fluid channels is substantially completelyobstructed by the plate.
 2. The rotary valve system of claim 1, whereinthe first plurality of fluid channels diverge within the first valvebody.
 3. The rotary valve system of claim 1, wherein the secondplurality of fluid channels converge within the second valve body. 4.The rotary valve system of claim 1, wherein the second outlet is acommon outlet in fluid communication with a single outlet duct.
 5. Therotary valve system of claim 1, wherein the second outlet of each one ofthe second plurality of fluid channels is in fluid communication with arespective one of a plurality of outlet ducts.
 6. The rotary valvesystem of claim 1, further comprising an actuator coupled to the plateassembly that is responsive to one or more control signals to move theplate between the first, closed position, the second, open position andpositions in-between the first, closed position and the second, openposition.
 7. The rotary plate valve system of claim 6, wherein the plateassembly further comprises a gear having a plurality of gear teethcoupled to the actuator and rotatable by the actuator, and the plateincludes a plurality of plate gear teeth that meshingly engage with theplurality of gear teeth such that the rotation of the gear moves theplate between at least the first, open position and the second, closedposition.
 8. The rotary plate valve system of claim 1, wherein thesecond valve body includes a shaft defined internally within the secondvalve body and the plate is coupled to the shaft for movement relativeto the second plate body and the first plate body.
 9. The rotary platevalve system of claim 1, wherein the first plurality of fluid channelscomprise four first fluid channels defined within the first valve bodythat are spaced apart about a perimeter of the first valve body and thesecond plurality of fluid channels comprise four second fluid channelsdefined within the second valve body that are spaced apart about aperimeter of the second valve body, with each one of the first fluidchannels in selective fluid communication with a respective one of thesecond fluid channels.
 10. The rotary plate valve system of claim 9,wherein each one of the four first fluid channels extends from thecommon first inlet along a common wall and diverges downstream from thecommon first inlet to define a cavity, with a portion of the plateassembly received within the cavity.
 11. The rotary plate valve systemof claim 1, wherein a first sub-plurality of the second plurality offluid channels are in fluid communication with a plurality of surgeducts and a second sub-plurality of the second plurality of fluidchannels are in fluid communication with a plurality of load ducts, afirst sub-plurality of the first plurality of fluid channels are inselective fluid communication with the first sub-plurality of the secondplurality of fluid channels and a second sub-plurality of the firstplurality of fluid channels are in selective fluid communication withthe second sub-plurality of the second plurality of fluid channels. 12.A rotary valve system, comprising: a first valve body having a firstplurality of fluid channels, each one of the first plurality of fluidchannels having a common first inlet to receive a fluid and a firstoutlet, the first plurality of fluid channels diverging downstream ofthe common first inlet; a second valve body coupled to the first valvebody, the second valve body having a second plurality of fluid channels,each one of the second plurality of fluid channels having a second inletand a common second outlet; and a plate assembly having a plate coupledbetween the first valve body and the second valve body, the platedefining a plurality of openings, the plate movable between at least afirst, open position in which each first outlet of the first pluralityof fluid channels is in fluid communication with a respective secondinlet of the second plurality of fluid channels and a second, closedposition in which the second inlet of each of the second plurality offluid channels is substantially completely obstructed by the plate. 13.The rotary valve system of claim 12, further comprising an actuatorcoupled to the plate assembly that is responsive to one or more controlsignals to move the plate between the first, closed position, thesecond, open position and positions in-between the first, closedposition and the second, open position.
 14. The rotary plate valvesystem of claim 13, wherein the plate assembly further comprises a gearhaving a plurality of gear teeth coupled to the actuator and rotatableby the actuator, and the plate includes a plurality of plate gear teeththat meshingly engage with the plurality of gear teeth such that therotation of the gear moves the plate between at least the first, openposition and the second, closed position.
 15. The rotary plate valvesystem of claim 12, wherein the second valve body includes a shaftdefined internally within the second valve body and the plate is coupledto the shaft for movement relative to the second plate body and thefirst plate body.
 16. The rotary plate valve system of claim 12, whereinthe first plurality of fluid channels comprise four first fluid channelsdefined within the first valve body that are spaced apart about aperimeter of the first valve body and the second plurality of fluidchannels comprise four second fluid channels defined within the secondvalve body that are spaced apart about a perimeter of the second valvebody, with each one of the first fluid channels in selective fluidcommunication with a respective one of the second fluid channels. 17.The rotary plate valve system of claim 16, wherein each one of the fourfirst fluid channels extends from the common first inlet along a commonwall and diverges downstream from the common first inlet to define acavity, with a portion of the plate assembly received within the cavity.18. The rotary plate valve system of claim 16, wherein each one of thefour second fluid channels extends from the second inlet and convergesdownstream from the second inlet along a second common wall upstreamfrom the second outlet.
 19. A rotary valve system, comprising: a firstvalve body having a first plurality of fluid channels, each one of thefirst plurality of fluid channels having a common first inlet to receivea fluid and a first outlet; a second valve body coupled to the firstvalve body, the second valve body having a second plurality of fluidchannels, each one of the second plurality of fluid channels having asecond inlet and a second outlet, the second plurality of fluid channelsconverging within the second valve body downstream from the secondinlet; and a plate assembly having a plate coupled between the firstvalve body and the second valve body, the plate defining a plurality ofopenings, the plate movable between at least a first, open surgeposition in which the first outlet of a first sub-plurality of the firstplurality of fluid channels is in fluid communication with the secondinlet of a first sub-plurality of the second plurality of fluidchannels, a second, closed position in which the second inlet of each ofthe second plurality of fluid channels is substantially completelyobstructed by the plate, and a third, open load position in which thefirst outlet of a second sub-plurality of the first plurality of fluidchannels is in fluid communication with the second inlet of a secondsub-plurality of the second plurality of fluid channels.
 20. The rotaryplate valve system of claim 19, wherein the plate assembly furthercomprises a gear having a plurality of gear teeth coupled to an actuatorand rotatable by the actuator, the plate includes a plurality of plategear teeth that meshingly engage with the plurality of gear teeth suchthat the rotation of the gear moves the plate between at least thefirst, open surge position, the second, closed position and the third,open load position.